Ford Crown Victoria 1998 4.6l Sfi Workshop Manual

ford :: Ford Crown Victoria V8-281 4.
6L SFI (1998
)
> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Passive Anti-Theft System
Alarm Module: LocationsPassive Anti-Theft System Module

Instrument Panel View
The Passive Anti-Theft System Module is located at the LH side of the instrument panel.
> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Passive Anti-Theft System
Alarm Module: LocationsPassive Anti-Theft System Transceiver Module

The Passive Anti-Theft System Transceiver Module is located at the LH side of the instrument panel.
> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Mo
Passive Anti-Theft System Control Module

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Mo
Passive Anti-Theft System Transceiver Module

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 12
Alarm Module: Service and Repair

Removal
1. Disconnect battery ground cable.2. Remove the steering column opening cover assembly and reinforcement to acc
junction panel.
3. Remove three fasteners retaining module and bracket and one fastener attaching metal brace near module. 4. Disco
PATS Control Module
Installation
Note:
The PATS module must be reconfigured after replacement. Two encoded keys must be cycled in ignition first and th
into the control module.
4. Configure the module as necessary (B2139). 5. To program additional keys, follow Key Programming Program a
Equipment/Antitheft and Alarm Systems/Service and Repair
2.4-4.0 Nm (22-35 lb-in). 1. To install, reverse the removal procedure. 2. Tighten all three screws to 3. Install an enc
> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Driver's Door Module <--> [Keyless Entry Module] > Component Information > Service and Repair
Driver's Door Module: Service and Repair

REMOVAL
1. Disconnect battery ground cable.
2. Remove LH front door trim panel.3. Disconnect body main wiring from driver door module.4. Remove two screw
INSTALLATION
1. Follow removal procedure in reverse order.
> Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Locations
Door Module: Locations

Full Body View
The Left Front Door Module is located in the driver's door.
> Relays and Modules > Relays and Modules - Body and Frame > Driver's Door Module <--> [Keyless Entry Module] > Component Information > Service and Repair

REMOVAL
INSTALLATION
> Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Locations
Power Door Lock Control Module: Locations
The Driver's Door Module is located in center of the LH front door.

> Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions
Power Door Lock 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
> Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 28
Crown Victoria V8-281 4.6L SFI (1998)

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
The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution.

Sample System Diagram
System Diagrams
Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed

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 interconn
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution.
Symbol Identification

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols
Wire Color Code Identification

BK
BL
BR
DB: Black: Blue: Brown: Dark Blue

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
Y: Dark Green: Gray: Green: Light Blue: Light Green: Pink: Orange: Purple: Red: Tan: Violet: White: 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 list
> Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3
Power Door Lock Control Module: Connector Views
Driver's Door Module (C519)


> Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3
Power Door Lock Control Module: Electrical Diagrams

Driver's Door Module (Part 1 Of 3)


> Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Page 40
Power Door Lock Control Module: Service and Repair

REMOVAL
INSTALLATION
> Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Locations
Power Mirror Control Module: Locations

> Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions
Power Mirror Control Module: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 53
Power Mirror Control Module: Connector Views


> Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 55
Power Mirror Control Module: Electrical Diagrams



> Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Driver's Door Module
Power Seat Control Module: LocationsDriver's Door Module

> Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Driver's Door Module > Page 62
Power Seat Control Module: LocationsDriver's Seat Module

Front Seat Assemblies
The Driver's Seat Module is located below the driver's seat.

> Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions
Power Seat Control Module: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Page 65

> Page 66

System Diagrams
> Page 67

Grounds Diagrams
> Page 68

ELECTRICAL SYMBOLS
Electrical Symbols
> Page 69

Electrical Symbols
VACUUM SYMBOLS
> Page 70

Vacuum Symbols

BK
BL
BR
> Page 71

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 72
Power Seat Control Module: Connector Views

> Page 73

> Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 74
Power Seat Control Module: Electrical Diagrams

> Page 75

> Page 76

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest
> 98-19-7 > Sep > 98 > Engine - Hesistation When Accelerating
Electronic Brake Control Module: Customer InterestEngine - Hesistation When Accelerating
Article No.98-19-7
09/28/98
HESITATION - DURING ACCELERATION WITHTRACTION CONTROL ACTIVATED - VEHICLES BUILTTH
FORD:1998 CROWN VICTORIA
LINCOLN-MERCURY:1998 GRAND MARQUIS, TOWN CAR
ISSUE
Some vehicles may hesitate on acceleration when the traction control system is activated. This may be caused by the Po
ACTION
Replace the ABS module with a revised ABS module and reprogram the PCM with the latest level calibration. Strategy
NOTE
THE ABS MODULE PRODUCTION PART NUMBER IS LOCATED ON THE INBOARD SURFACE OF THE
SERVICE PROCEDURE
1. Install memory saver, then disconnect battery negative cable.
2.
Replace the ABS Module (F8AZ-2C219-BA). Refer to 1998 Crown Victoria/Grand Marquis Service Manual, Se
3. Connect battery cable, then remove memory saver.

4.
Reprogram the PCM to updated calibration using Service Bay Diagnostic System (SBDS) or New Generation Sta
NOTE
PCM REPLACEMENT IS NOT AUTHORIZED BY THIS TSB. REFER TO THE POWERTRAIN CONTROL/EM
SERVICE MANUAL FOR APPROPRIATE
> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins >
Customer Interest for Electronic Brake Control Module: > 98-19-7 > Sep > 98 > Engine - Hesistation When Accelerating > Page 86

DIAGNOSTIC PROCEDURES IF PCM HARDWARE CONCERNS EXIST.
Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer n
PART NUMBER PART NAME
F8AZ-2C219-BA ABS Module
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To B
OPERATION DESCRIPTION TIME
981907A Replace ABS Module And 0.9 Hr.
Reprogram PowertrainControl Module (PCM)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2C219 42
OASIS CODES: 301000, 607000, 607500, 611000, 611500, 614000, 614500

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Serv
Control Module: > 98-19-7 > Sep > 98 > Engine - Hesistation When Accelerating
Electronic Brake Control Module: All Technical Service BulletinsEngine - Hesistation When Accelerating
Article No.98-19-7
09/28/98
ISSUE
ACTION
NOTE
SERVICE PROCEDURE
2.

4.
NOTE
> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Electronic Brake Control Module: > 98-19-7 > Sep > 98 > Engine - Hesistation When Accelerating > Page 92

DEALER CODING
CONDITION
BASIC PART NO. CODE
2C219 42
OASIS CODES: 301000, 607000, 607500, 611000, 611500, 614000, 614500

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 93
Electronic Brake Control Module: Specifications

Torx Bolts To Hydraulic Control Unit ................................................................................................................................
Electronic Brake Control Module: Locations

Engine View
The Anti-Lock Brake Module is located at the LH front of the vehicle, on front of the upper radiator support.
Anti-Lock Brake Module
Electronic Brake Control Module: Description and Operation

(HCU).
The anti-lock brake control module is mounted to the Hydraulic Control Unit It is an on-board diagnostic, replaceab
Under normal driving conditions, the microprocessor produces short test pulses to the solenoid valves that check
-
Impending wheel lock conditions trigger signals from the anti-lock brake control module that open and close the
- During normal braking, the brake pedal feel will be identical to a standard brake system.
- (DTC)
Most faults which occur to the anti-lock brake system and the traction control will be stored as a Diagnostic Trou
Electronic Brake Control Module: Service and Repair

REMOVAL
1. Remove hydraulic control unit.2. Disconnect 2-pin connector.3. Remove the four bolts.4. Slide anti-lock brake con
INSTALLATION
2 Nm (17 inch lbs.)1. Position anti-lock brake control module on brake pressure control valve block. Connect 2-pin
3. Install hydraulic control unit.

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest for Rad
00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating
00-10-3Technical Service Bulletin #
PCM - Engine Spark Knock While Accelerating
Article No.00-10-3
05/15/00
SPARK KNOCK - WHILE ACCELERATING IN TEMPERATURES OF 32 DEGREES C (90 DEGREES F)
FORD:1998-1999 CROWN VICTORIA
MERCURY:1998-1999 GRAND MARQUIS
ISSUEA spark knock may occur while accelerating in ambient temperatures greater than 32C (90F) on some vehicles.
ACTIONCheck the operation of the high and low speed cooling fans, and if necessary reprogram the Powertrain Contr
OTHER APPLICABLE ARTICLES: NONEWARRANTY STATUS: Eligible Under The Provisions Of Bumper To B
001003A Reprogram Powertrain 1.3 Hrs.

Control Module (PCM),Perform Octane AdjustProcedure And CheckOperation Of Cooling Fans(Als
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100
> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer
Interest for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 107

Service Procedure
1. Perform normal diagnostics and repair as required. If no faults are found, proceed to Step 2.
2. Verify high and low speed cooling fan operation using NGS and the following Steps.
3. Select DIAGNOSTIC DATA LINK.
4. Select PCM.
5. Select active command modes.
6. Select output test mode.
7. Select mode low fan.
8. Push START and verify low speed cooling fan operation. Push STOP.
9. Select mode high fan.
10. Push START and verify high speed fan operation. Push STOP.
11. Repair any faults found, test drive and retest for spark knock. If spark knock is still present, procedure to next Ste
12. Reprogram the PCM calibration using the Recalibration Chart listed in the TSB.
13. Test drive and retest for spark knock. If spark knock is still present, go to Step 14.
NOTE:
USE THIS PROCEDURE ONLY AS A FINAL STEP FOR VEHICLES EXHIBITING THIS CONCERN. THE SO
14.
Perform the Software Octane Adjust Procedure using NGS, the current service card and the flash cable. Make sur
15. Make sure the battery is fully charged.
16. Turn ignition key on.
17. Install the latest calibration card.

18. Select PCM programming.
19. Enter 8 numbers (anything, 22222222).
20. The window will show the calibration #.
21. Select TRIGGER..
22. Hook up the NGS cable.
23. Cycle the ignition key off, then on.
> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer
Interest for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 108

24. Select TRIGGER.
25. Turn the ignition key on.
26. Select YES.
27. The window will display the latest calibration.
28. Select YES to modify the PCM parameters.
29. Select OCTANE ADJUST.
30. Select RETARD using the thumbwheel.
31. Select START to activate octane adjust.
32. The window should display PCM update successfully completed.

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bul
Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating
Article No.00-10-3
05/15/00

DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100
> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 114

Service Procedure
4. Select PCM.
NOTE:
14.

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 115

24. Select TRIGGER.
26. Select YES.

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations
Radiator Cooling Fan Motor Relay: Locations

Engine View
> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 119

Engine Compartment Fuse Box
The Cooling Fan Relay (Relay 3) is located at the RH front of the engine compartment, in engine compartment fuse pa
> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 120

Cooling Fan
> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions
Radiator Cooling Fan Motor Relay: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1
Cooling Fan
> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 131
Radiator Cooling Fan Motor Relay: Testing and Inspection
For Testing and Inspection information please refer to Cooling System/Testing and Inspection/Procedures
> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations
Compressor Clutch Relay: Locations

Engine View
> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 136

Relay Center (C110)
The A/C Wide Open Throttle Cutout Relay is located at the LH side of the engine compartment, in relay center.
Compressor Clutch Relay: Description and Operation

RELAYS
The manual A/C-heater electrical system uses a relay and two pressure-sensitive switches to control system functions. T
- A/C clutch control relay.
- A/C pressure cut-off switch.
- A/C cycling switch.
A/C CLUTCH CONTROL RELAY
(PCM)
The A/C clutch control relay enables the A/C clutch when commanded by the Powertrain Control Module . The A/C cl
- engine start-up
- (WOT)Wide Open Throttle
- during low engine idle conditions
- excessively high engine temperatures
The A/C clutch control relay is a normally open relay connected in the A/C clutch circuit. When the relay is energized
Compressor Clutch Relay: Service and Repair
REMOVAL
1. Raise hood to gain access to relay center.2. Dislodge relay center from vacuum tank on LH wheel housing.3. Depr
INSTALLATION
> Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips
Control Module HVAC: Technical Service BulletinsClimate Control - Blower Control Service Tips
Article No.00-21-3
10/16/00
CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS
FORD: 1990-1993 THUNDERBIRD1990-2001 CROWN VICTORIA1995-2001 EXPLORER
LINCOLN: 1990-2001 TOWN CAR2000-2001 LS
MERCURY: 1990-1993 COUGAR1990-2001 GRAND MARQUIS1997-2001 MOUNTAINEER
ISSUEThe following service procedure has been developed to aid technicians in diagnosing EATC/DATC system blow
ACTIONRefer to the following Service Procedure as an aid in helping diagnose blower motor control concerns.
SERVICE PROCEDURE
1. Check blower motor operation in all speeds.
^ If the blower motor does not operate in any speed, refer to Step 2.
^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the Service/Work
^ If the blower motor does not operate in HIGH speed, refer to Step 3.
^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4.
> Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control - Blower Control
Service Tips > Page 143

NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW.
2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the EATC/DATC mod
EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage between the blower
a.
b.
If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor
3. Set the blower speed control to HIGH and measure the voltage between the blower motor control high blower rela
and ground at the EATC/DATC module connector.
a.
If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed co
b.
4. Set the blower speed control to any speed other than HIGH and measure the voltage between the blower motor con
2 at the controller) and ground at the EATC/DATC module.
a.
If the voltage is below 1 volt, measure the resistance between the blower motor speed controller connector
b.
If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower motor spee
c.
If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower motor speed c
> Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control - Blower Control
Service Tips > Page 144

OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 208000, 208300, 208999

> Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 145
Control Module HVAC: Locations

The Electronic Automatic Temperature Control Module is located at the center of the instrument panel.
> Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Blower Motor Speed Control
Blower Motor Speed Controller

> Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Blower Motor Speed Control > Page 148
Control Module HVAC: DiagramsElectronic Climate Control Module
Electronic Automatic Temperature Control Module (C228)

> Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Blower Motor Speed Control > Page 149

> Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Page 150
Control Module HVAC: Description and Operation
FIG. 18 Variable Blower/Controller High Blower Relay
The A/C blower motor speed control is located in the A/C evaporator core housing and is accessible through the engine
-
The function of the A/C blower motor speed control is to convert low power signals from the EATC assembly to
- A/C blower motor speed is infinitely variable and is controlled by the electronic control assembly software.
- A delay function provides a gradual increase or decrease in A/C blower motor speed under all conditions.
> Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Page 151
Control Module HVAC: Service and Repair
FIG. 22 Variable Blower Speed Controller (VBSC)
REMOVAL
1. Open hood.2. At dash panel, remove two nuts retaining fuel pressure regulator to cowl panel bracket.3. Locate A/C
INSTALLATION
2-3 N.m (18-26 lb-in).1. Position the A/C blower motor speed control assembly in the opening in the A/C evaporato
> Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Locations
Audible Warning Device Control Module: Locations

The Speed Chime Warning Module is located at the RH side of the instrument panel.
> Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Locations > Page 156
Speed Chime Module

> Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Description and Operation
Instrument Panel Control Module: Description and Operation
The indicator lamp module system consists of:

- Indicator lamp module.
- ABS indicator.
- Hazard warning indicator.
- Brake warning indicator.
- Traction control indicator.
The indicator lamp module informs the driver:

- When anti-lock brake system concern exists.
- When brake fluid level is low or the parking brake is engaged.
- When hazard flashers are operating.
- When a traction control event exists (indicator flashes).
- When the traction control system is disabled (indication ON steady).
> Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic O
Instrument Panel Control Module: Initial Inspection and Diagnostic Overview

1. Verify the customer's concern by observing the indicators to determine if they are operating properly with the igni
- In RUN without the engine running.
- In START before the ignition switch is released.
- In RUN with the engine running.
2. Inspect to determine if any of the electrical concerns apply:
VISUAL INSPECTION CHART
Electrical -
Fuse(15 A)Fusepanel:-
junction 13 .
- Circuit wiring.
- Switches or sensors.
3. If inspection reveals obvious concerns that can be readily identified, service as required.4. If the concern(s) remain
Procedures
> Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic O
> Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Service and Repair > Indicator Bulb
Instrument Panel Control Module: Service and RepairIndicator Bulb

REMOVAL
1. Remove indicator lamp module.2. Turn bulb counterclockwise and pull out.
INSTALLATION
1. To install, reverse removal procedure.
> Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Service and Repair > Indicator Bulb > Page 165
Instrument Panel Control Module: Service and RepairIndicator Lamp Module

REMOVAL
1. Turn ignition switch OFF.2. Gently insert a small, flat screwdriver into one of either access slots located on the ve
lamp module depressing the mounting tab toward the indicator lamp module. Apply a light outward force to free
4. Pull indicator lamp module from instrument panel and disconnect connector.
INSTALLATION
1. Connect indicator lamp module connector.2. Snap indicator lamp module into instrument panel opening.
> Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations
Daytime Running Lamp Control Unit: Locations

Engine View
The Daytime Running Lamps Module is located at the center front of the vehicle, on front of upper radiator support.
> Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 170
Daytime Running Lamps Module

> Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Service and Repair > Control Module
Daytime Running Lamp Control Unit: Service and RepairControl Module
REMOVAL
1. Disconnect electrical connector from daytime running lamps control.
WARNING: DAYTIME RUNNING LAMPS CONTROL GETS VERY HOT DURING OPERATION. BE
2. Remove screw retaining daytime running lamps control to radiator support.
INSTALLATION
> Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Service and Repair > Control Module > Page 173
Daytime Running Lamp Control Unit: Service and RepairParking Brake Signal Switch
REMOVAL
1. Disconnect parking brake signal switch electrical connector.2. Remove screw and parking brake signal switch.
INSTALLATION
> Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Exterior Ligh
Turn Signals - Intermittent Rapid Flashing
Exterior Lighting Module: Customer InterestTurn Signals - Intermittent Rapid Flashing
Article No.02-9-7
05/13/02
ELECTRICAL - LAMP - INTERMITTENT RAPIDFLASHING OF THE TURN SIGNALS - VEHICLESPRODUCE
This article is being republished in its entirety to update the Service Procedure and to update the parts required.
ISSUESome vehicles produced before 3/5/2002 may exhibit an intermittent rapid flashing of the turn signals. This may
ACTIONIf condition is not resolved, replace the Lighting Control Module with the latest level part. Refer to the follow
SERVICE PROCEDURE
If normal diagnostics does not correct the condition, replace the Lighting Control Module with the latest engineering le
1
Disconnect the battery ground cable. For additional information refer to Workshop Manual Section 14-01 for 199
2. Remove the LH instrument panel lower insulator (Figure 1).
a. Remove the pin-type retainers (Figure 1, Detail 1).
b. Disconnect the courtesy lamp (Figure 1, Detail 2).
3.
If equipped with adjustable pedals (model years 2001-2002), remove the accelerator pedal and shaft. For addition
> Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > Customer Interest
for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing > Page 182

4. Position the LCM aside.
a. Remove the screws (Figure 2, Detail 1).
b. Release the locking tab (Figure 2, Detail 2).

5. Disconnect the electrical connectors and remove the LCM (Figure 3).
6. To install, reverse the removal procedure. Check for correct operation.
SUPERSEDES: 01-21-3
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
> Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > Customer Interest

13C788 42
OASIS CODES: 201000, 201100, 201200, 206000

> Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
May > 02 > Turn Signals - Intermittent Rapid Flashing
Exterior Lighting Module: All Technical Service BulletinsTurn Signals - Intermittent Rapid Flashing
Article No.02-9-7
05/13/02
SERVICE PROCEDURE
1
3.
> Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing > Page 189


SUPERSEDES: 01-21-3
DEALER CODING
CONDITION
BASIC PART NO. CODE
> Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Technical

13C788 42
OASIS CODES: 201000, 201100, 201200, 206000

> Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Police Option Emergency Flasher Relay #1
Hazard Flasher Relay: LocationsPolice Option Emergency Flasher Relay #1

The Police Option Emergency Flasher Relay #1 is located at the LH rear of the trunk.
> Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Police Option Emergency Flasher Relay #1 > Page 195

> Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations
Horn Relay: Locations

Engine View
> Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 199

The Horn Relay (Relay 2) is located at the RH front of the engine compartment, in engine compartment fuse box.
> Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 200
Horn Relay: Service and Repair

REMOVAL
1. Open the hood.2. Disconnect battery ground cable.3. Open power distribution box located on the RH side.4. Pull o
INSTALLATION
> Relays and Modules > Relays and Modules - Lighting and Horns > Lighting Control Module (LCM) <--> [Lamp Control Module] > Component Information > Locations
Lighting Control Module (LCM): Locations

The Lighting Control Module is located behind LH side of the instrument panel.
> Relays and Modules > Relays and Modules - Lighting and Horns > Lighting Control Module (LCM) <--> [Lamp Control Module] > Component Information > Diagrams > Diagram Inform
Lighting Control Module (LCM): Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Relays and Modules > Relays and Modules - Lighting and Horns > Lighting Control Module (LCM) <--> [Lamp Control Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 206


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
Lighting Control Module (LCM): Connector Views
Lighting Control Module (C2026)



Lighting Control Module (LCM): Electrical Diagrams

Lighting Control Module (Part 1 Of 3)


> Relays and Modules > Relays and Modules - Lighting and Horns > Lighting Control Module (LCM) <--> [Lamp Control Module] > Component Information > Diagrams > Page 219
Lighting Control Module (LCM): Description and Operation
This vehicle uses a lighting control module. This eliminates the electronic interference and heat associated with the the
> Relays and Modules > Relays and Modules - Lighting and Horns > Lighting Control Module (LCM) <--> [Lamp Control Module] > Component Information > Diagrams > Page 220
Lighting Control Module (LCM): Service and Repair

REMOVAL
1. Remove instrument panel lower insulator.2. Locate lighting control module above accelerator pedal.3. Disconnect
INSTALLATION
> Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations
Turn Signal Relay: Locations

> Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations > Page 224

Multi Function Switch
The Turn Signal Flasher output is provided by the Lighting Control Module, which is located behind the LH side of the
> Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Police Power Relay
Power Distribution Relay: LocationsPolice Power Relay

Engine View
> Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Police Power Relay >
Page 230

The Police Power Relay (Relay 4) is located at the RH front of the engine compartment, in engine compartment fuse bo
> Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Police Power Relay > Page 231
Power Distribution Relay: LocationsTrailer Battery Charging Relay

The Trailer Battery Charging Relay is located at LH side of the trunk, on support.
Power Distribution Relay: LocationsTrailer Exterior Lamps Relay

The Trailer Exterior Lamps Relay is located at LH side of the trunk, on support.
Power Distribution Relay: LocationsTrailer Left Turn Relay

The Trailer Left Turn Relay is located at LH side of the trunk, on support.
Power Distribution Relay: LocationsTrailer Right Turn Relay

The Trailer Right Turn Relay is located at LH side of the trunk, on support.
> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay Center
> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay Center > Page 239
Relay Center (C110)

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Tech
Controls - General PCM Programming Procedures
Engine Control Module: Technical Service BulletinsEngine Controls - General PCM Programming Procedures
TSB 04-24-14
12/13/04
FORD:1997 Thunderbird1997-2000 Contour1997-2002 Escort1997-2005 Crown Victoria, Mustang, Taurus2000-2003
LINCOLN:1997-1998 Mark VIII1997-2002 Continental1997-2005 Town Car2000-2005 LS1997-2005 Navigator2003
MERCURY:1997-1999 Tracer1997-2000 Mystique1997-2002 Cougar1997-2005 Grand Marquis, Sable2005 Montego
This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain c
ISSUEPCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused
ACTIONUse 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.
> 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 246

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, NG
NOTE
IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS,
PCM REPLACEMENT - STANDARD
1.
Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communica
2. Install the new PCM.
NOTE
IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED
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 pe
b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as t
6. Check for DTC B2900.
a.
If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedur
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
6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank
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 ste
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 KE

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
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 pre
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: V
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
WARRANTY STATUS: Information Only
Disclaimer
Controls - General PCM Programming Procedures > Page 248
Engine Control Module: Technical Service BulletinsPCM - Reprogramming Out of Vehicle
Article No.99-4-3
03/08/99
REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES O
FORD:1994-97 THUNDERBIRD1994-99 MUSTANG1995-99 CROWN VICTORIA1996-97 PROBE1996-99 CONT
LINCOLN-MERCURY:1994-97 COUGAR1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR1996-98 M
LIGHT TRUCK:1994-97 F SUPER DUTY, F-250 HD, F-3501995-99 ECONOLINE, RANGER, WINDSTAR1996 B
This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart
ISSUEThe Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be

ACTIONRefer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary
Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket
The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration
The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA.
SUPERSEDES: 98-26-3
OASIS CODES: 203000, 206000, 290000, 690000, 698298
Engine Control Module: Specifications

Engine Control Sensor Wiring Connector to PCM Bolt ......................................................................................................
Engine Control Module: Locations

Engine View
The Powertrain Control Module is located behind LH side of instrument panel, on LH side of the safety wall.
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diag
Instructions
Engine Control Module: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
Information > Diagrams > Diagram Information and Instructions > Page 254


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
Engine Control Module: Connector Views

Powertrain Control Module (Part 1 Of 2)

Engine Control Module: Description and Operation
Powertrain Control Module (PCM)
(PCM)The Powertrain Control Module performs the following functions:

-
accepts information from various engine sensors to compute the required fuel flow rate necessary to maintain a p
- sends out a command to the fuel injectors to meter the appropriate quantity of fuel
- determines and compensates for the age of the vehicle and its uniqueness
- automatically senses and compensates for changes in altitude (for example, from sea level to mountains)
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Serv
Engine Control Module: Procedures

(PCMs)Powertrain Control Modules are reprogrammable to update calibration levels without having to replace the PC
(SBTS).The reprogramming may be performed with the PCM installed in the vehicle using the Service Bay Technical
(NGS)
The PCM may also be reprogrammed outside of the vehicle using the New Generation STAR and a 15- to 104- Pin Fla
266
Engine Control Module: Reset Procedure

NOTE: Powertrain Control Module (PCM) reset All OBD II scan tools support the .
The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. W
(DTCs).
-The Clears
following the number
events of Diagnostic
occur when Trouble
a PCM reset Codes
is performed:
- 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: (NGS)
When using the New Generation STAR Scan Tool to perform a PCM reset, press the CLEAR button. This func
New Generation STAR and Generic Scan Tool

Refer to the scan tool manufacturer's manual for specific instructions on how to perform PCM reset.
Keep Alive Random Access Memory 5 minutes.

To reset , disconnect the battery ground cable for a minimum of Resetting Keep Alive RAM will clearlearned values th
After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to driv
267
Engine Control Module: Removal and Replacement
(PCM)
3.7 Nm (32 lb in)1. Disconnect battery ground cable.2. Loosen engine control sensor wiring to PCM connector retai
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Integrated Control Relay Module > Component Informati
Relay Center (C110)

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Inform
Main Relay (Computer/Fuel System): Locations

Engine View
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) >
Component Information > Locations > Page 274

Relay Center (C110)
The PCM Power Relay is located at the LH side of the engine compartment, in relay center.
> 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 View
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component
Information > Locations > Page 279

Relay Center (C110)
The Fuel Pump Relay is located at the LH side of the engine compartment, in relay center.
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams >
Instructions
Fuel Pump Relay: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
Fuel Pump Relay: Description and Operation

(PCM)
The fuel pump relay supplies power to the fuel pump when the Powertrain Control Module grounds the relay during S
Fuel Pump Relay: Service and Repair
1. Disconnect battery ground cable.2. Locate fuel pump relay in the engine compartment power distribution center an
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Integrated Control Relay Module > Component Informati
Relay Center (C110)

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Inform

Engine View
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) >

Relay Center (C110)
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations
Ignition Control Module: Locations

The ignition control module is integrated within the powertrain control module. It is not a separately replaceable compo
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 30
Ignition Control Module: Description and Operation

PURPOSE
- (ICM) (PCM)
The Ignition Control Module is incorporated within the Powertrain Control Module . The ICM receives engine p
OPERATION
- The ICM synthesizes a profile ignition pick up signal and ignition diagnostic monitor signal for use within The P
-
The PCM uses this information to determine which ignition coil to fire, calculating the turn ON/OFF times of the
> Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Electronic Crash Sensor <--> [Air Bag Control Module] > Component Information > Specifications
Air Bag Electronic Crash Sensor: Specifications

Description N.m (Lb-In) ....................................................................................................................................................
10.2-13.8 (90-122)Air Bag Electronic Crash Sensor Module Screws..................................................................................

> Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Electronic Crash Sensor <--> [Air Bag Control Module] > Component Information > Specifications > Page 307
Air Bag Electronic Crash Sensor: Locations

> Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Electronic Crash Sensor <--> [Air Bag Control Module] > Component Information >
Specifications > Page 308

The Air Bag Electronic Crash Sensor (Air Bag Control Module) is located behind RH side (Passenger Side) of the instr
> Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Electronic Crash Sensor <--> [Air Bag Control Module] > Component Information > Specifications > Page 309
Air Bags Electronic Crash Sensor

> Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Electronic Crash Sensor <--> [Air Bag Control Module] > Component Information > Description and Operation >
ECS) Module
Air Bag Electronic Crash Sensor: Description and OperationAir Bag Electronic Crash Sensor (ECS) Module
(ECS)The air bag Electronic Crash Sensor module:

^ discriminates between events that warrant frontal air bag deployment and events that do not.
^ provides current to the inflators to deploy the air bags in the event of a deployable crash.
^ (SRS)monitors the air bag Supplemental Restraint System for faults.
^ illuminates the air bag indicator if a fault is detected.
^ (LFC)flashes the air bag indicator to indicate the Lamp Fault Code detected.
^ (DLC) (DTCs)communicates through the Data Link Connector the current and historical Diagnostic Trouble Co
^ activates a chime if the air bag indicator is not available.
Several important features of the ECS and its functions within the system are described. See: Air Bag System Function
> Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Electronic Crash Sensor <--> [Air Bag Control Module] > Component Information > Description and Operation >
ECS) Module > Page 312
Air Bag Electronic Crash Sensor: Description and OperationAir Bag System Functions
Air Bag Indicator Lamp
^ (ECS) six seconds
The air bag Electronic Crash Sensor module illuminates the AIR BAG indicator for approximately when the ign
^ (LFCs) 30 seconds
Lamp Fault Codes , if present, will begin flashing approximately after the ignition switch has been turned to RU
^ LFCs are displayed as a series of flashes and pauses of the AIR BAG indicator. LFCs are two-digit numbers.
Example: An LFC 32 is displayed as follows:

(two second pause)
(five second pause)
(two second pause)
(five second pause)flash flash flash - - flash flash - ... flash flash flash - - flash flash - ...
^ LFCs are prioritized numerically so that if two or more faults occur at the same time, the LFC with the highest pr
^ After the LFC is displayed five times, the air bag indicator will illuminate continuously until the ignition switch i
^ (NVRAM) (DTCs)
The ECS incorporates Non-Volatile Random Access Memory to store Diagnostic Trouble Codes and retain them
^
one minuteThe ECS includes an internal backup power supply. This feature provides sufficient backup power to
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE

^
The ECS incorporates an internal safing sensor. Proper mounting of the ECS and bracket assembly is critical to th
^ The ECS is non-serviceable and must be replaced as a unit in the event of failure.
If a system fault exists and the air bag warning indicator is not functioning, an audible chime will be heard indica
> Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Electronic Crash Sensor <--> [Air Bag Control Module] > Component Information > Service and Repair > Air B
Air Bag Electronic Crash Sensor: Service and RepairAir Bag Electronic Crash Sensor (ECS)
REMOVAL
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BAC
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can resu
NOTE:
Repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the or
(ECS)
1. Disconnect the battery ground cable.2. Remove the RH cowl side trim panel.3. Disconnect the air bag Electronic C
INSTALLATION
WARNING: THE TIGHTENING TORQUE OF THE AIR BAG ELECTRONIC CRASH SENSOR (ECS) MO
NOTE: Make sure to tighten the retaining nuts to specification.
1. Follow the removal procedure in reverse order.

> Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Electronic Crash Sensor <--> [Air Bag Control Module] > Component Information > Service and Repair > Air B
Page 315
Air Bag Electronic Crash Sensor: Service and RepairService of Air Bag Equipped Vehicles Involved In Collision
Air Bag Equipped Vehicles Involved In Collisions
While servicing an air bag-equipped vehicle that has been involved in a collision, check air bag electronic crash sensor
Sensors (ECS)
TheDamaged ECS modules

air bag Electronic Crashshould
Sensorbemodule
replaced whether oris not
orientation the driver
critical air bag
for proper air module or passenger
bag system operation.airIfbag module
a vehicle eq
> Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations
Starter Relay: Locations

> Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 320

The Starter Relay is located in the High Current Relay Center.
Starter Relay: Description and Operation

The starter interrupt relay consists of the following:
- Pull-in coil
- Contacts
When the ignition switch is in the START position:

- The pull-in coil is activated and pulls the contacts together.
- Current passes through the starter relay from the engine compartment power distribution box to the starter soleno
Starter Relay: Service and Repair

REMOVAL
1. Disconnect battery ground cable.2. Remove engine compartment power distribution box cover.3. Remove starter r
INSTALLATION
1. Follow removal procedure in reverse order.2. Align starter relay terminals with engine compartment power distrib
> Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations
Steering Control Module: Locations

The Electronic Variable Orifice Steering Module is located behind RH side of the instrument panel, above glove box.
> Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > With Air Suspe
Steering Control Module: DiagramsWith Air Suspension
Air Suspension/EVO Steering Module (C216)

> Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams >
With Air Suspension > Page 330

> Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > With Air Suspe
Electronic Variable Orifice Steering Module (Without Air Suspension)

> Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > Page 332
Steering Control Module: Description and Operation
TheAt low vehicle

control modulespeeds, thea power
contains steering control
microprocessor which valve actuator
analyzes is controlled
the vehicle to provide
speed sensor inputfull
andpump flow for
the shock full p
absorber
-
At higher vehicle speeds, the power steering control valve actuator is controlled to reduce power steering pump f
-
For evasive maneuvering at high speeds, the power steering control valve actuator is controlled to increase the po
-
With the addition of computer controlled air suspension, the air suspension control module is a dual-function mo
> Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > Page 333
Steering Control Module: Service and Repair
REMOVAL
WARNING: TURN AIR SUSPENSION SWITCH OFF TO PREVENT VEHICLE DAMAGE OR PERSONA
1. Remove glove compartment.2. Remove control module from snap-in fingers on bracket behind glove compartmen
INSTALLATION
1. Connect control module electrical connectors to control module.2. Install control module to bracket snap-in finger
> Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Loc
Control)
Compressor/Pump Relay: LocationsCompressor Relay (Level Control)

Engine View
The Compressor Relay is located at the RH front of engine compartment, in the engine compartment fuse box.
Control) > Page 339
Compressor/Pump Relay: LocationsSuspension Pump Relay

The Air Suspension Pump Relay (Relay 4) is located in engine compartment fuse box.
Compressor/Pump Relay: Description and Operation
- A relay is needed because the control module cannot directly provide the high current needed to run the compress
- The control module grounds Circuit 420 (DB/Y) to energize the relay coil.
- When energized, the coil creates a magnetic field which closes the relay contacts, connecting Circuit 1053 (LB/P
- High current then flows from battery to the compressor motor.
Compressor/Pump Relay: Service and Repair
REMOVAL
Remove cover from power distribution box (located at rear of battery) and remove relay.
INSTALLATION
Install new relay in power distribution box and install cover.
> Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations
Suspension Control Module: Locations

The Air Suspension Module is located behind RH side of the instrument panel, above glove box.
> Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 345
Suspension Control Module: Diagrams

> Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information >
Locations > Page 346

Suspension Control Module: Description and Operation
DESCRIPTION
The control module has the following features:
- Power is provided by Circuit 1053 (LB/PK).
- The air suspension switch is powered through Circuit 429 (PK/LG).
- Control module ground is provided through control module wire harness Pin 6, to the RH front passenger sheet m
- (EVO)The rear air suspension control module also controls the electronic variable orifice power steering.
- The wiring harness connects to the control module using two separate push button release connectors.
- The connectors are keyed so that they cannot be installed incorrectly.
OPERATION
Control module operates as follows:
- In general the control module uses a 40.5-second averaging interval to determine when compress and vent operat
-
However, door lamp switch inputs can override the 40.5-second averaging interval so compress and vent operatio
- The 40.5-second averaging interval is used to keep the control module from making unneeded corrections.
-
When a vehicle at the correct rear trim height hits a bump, the air suspension height sensor output will read low a
- If the control module was to correct for these "bump induced readings", system duty cycle would increase unnece
-
The 40.5-second averaging interval not only eliminates corrections due to bumps, but also eliminates unneeded c
-
Vent operations are more restricted with the ignition switch in RUN. Compress operations are more restricted aft
-
- The control module does not allow any vent operations for the first 45 seconds after the ignition switch has been
- Even if a vehicle is extremely high in the rear, DO NOT expect it to vent until the ignition switch has been turned
To eliminate the chance of catching a door on a curb as the vehicle vents down, the control module will not allow
Suspension Control Module: Service and Repair
REMOVAL
WARNING: TURN AIR SUSPENSION SWITCH OFF TO PREVENT VEHICLE DAMAGE OR PERSO
INSTALLATION
> Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation
Control Module: Description and Operation
The transmission control switch is a momentary contact switch located on the end of the transmission range selector
> Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations
Heated Glass Element Relay: Locations

Engine View
> Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 358

The Rear Defogger Relay (Relay 1) is located at the RH front of the engine compartment, in engine compartment fuse
> Relays and Modules > Relays and Modules - Windows and Glass > Driver's Door Module <--> [Power Window Control Module] > Component Information > Locations > Driver's Door M
Driver's Door Module: LocationsDriver's Door Module

> Relays and Modules > Relays and Modules - Windows and Glass > Driver's Door Module <--> [Power Window Control Module] > Component Information > Locations > Driver's Door M
Driver's Door Module: LocationsOne Touch Down Power Window Module

The One Touch Window Down Module is located in center of the LH front door, near master window/door lock contro
> Relays and Modules > Relays and Modules - Windows and Glass > Driver's Door Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Inform
Driver's Door Module: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Relays and Modules > Relays and Modules - Windows and Glass > Driver's Door Module <--> [Power Window Control Module] > Component Information > Diagrams >


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
Driver's Door Module: Connector Views
Driver Door Module



One Touch Window Down Module
Driver's Door Module: Electrical Diagrams



> Relays and Modules > Relays and Modules - Windows and Glass > Driver's Door Module <--> [Power Window Control Module] > Component Information > Diagrams > Page 379

REMOVAL
INSTALLATION
> Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations
Wiper Control Module: Locations

The Wiper Control Module is located behind instrument panel, near RH side of the steering column, above the warning
> Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 384
Wiper Control Module (C294)

> Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 385
Wiper Control Module: Service and Repair
REMOVAL
1. Disconnect battery ground cable.2. Remove instrument panel ash receptacle.3. Disconnect electrical connector fro
INSTALLATION
> Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp
Underhood Lamp Switch: Technical Service BulletinsHood Lamp Switch - Updated Replacement Part
Article No.01-19-4
10/01/01
ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOO
FORD: 1990-1995 ESCORT1990-2000 CROWN VICTORIA1991 TAURUS1992-1995 E SERIES1994 F-150, F-250,
LINCOLN: 1888-1989 MARK VII2000-2001 TOWN CAR2002 BLACKWOOD
MERCURY:1990-1995 GRAND MARQUIS, TRACER 1993-1998 VILLAGER
ISSUEThis article is to provide information on replacement hood lamp switches. The 14 degree Mercury style hood sw
ACTIONFor vehicles requiring hood lamp switch replacement, replace the 14 degree Mercury switch with new 14 deg
PARTS BLOCK
OTHER APPLICABLE ARTICLES: NONEWARRANTY STATUS: INFORMATION ONLYOASIS CODES: 20100

> Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Master
Master Window/Door Lock Control Switch
> Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Master > Page 397
> Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 398
Power Door Lock Switch: Testing and Inspection

Testing should be performed with the window regulator control switch removed from the vehicle. Use an ohmmeter.
5 ohms
5 ohms
1. Activate door lock switch to unlock. Resistance between Terminals 7 and 5 should be less than .2. Activate door lo
> Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 399
Power Door Lock Switch: Service and Repair

REMOVAL
1. Remove two screws retaining window regulator switch plate to the front door trim panel. Raise front door trim pan
INSTALLATION
> Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams
Power Mirror Switch

> Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 403
Power Mirror Switch: Service and Repair
REMOVAL
1. Pull window regulator switch plate loose from front door trim panel.2. Disconnect electrical connector from outsid
INSTALLATION
> Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Height Position Sensor
Power Seat Motor Position Sensor: LocationsHeight Position Sensor
Front
The Front Height Position Sensor is located under LH front seat.

Rear
> Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Height Position Sensor >
Page 408

The Rear Height Position Sensor is located under LH front seat.

> Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Height Position Sensor > Page 409
Power Seat Motor Position Sensor: LocationsHorizontal Position Sensor

The Horizontal Position Sensor is located under LH front seat.

> Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Height Position Sensor > Page 410
Power Seat Motor Position Sensor: LocationsRecliner Position Sensor

The Recliner Position Sensor is located at the LH rear of the LH front seat.
> Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > With Power Reclining Seats
Driver's & Passenger's Seat Control Switch

> Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > With Power Reclining Seats > Page 415
Driver's Seat Control Switch (Base Vehicle And Police Option)

> Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Power-Six-Way With Power Recliner
Power Seat Switch: Service and RepairPower-Six-Way With Power Recliner
REMOVAL
1. Disconnect battery ground cable.2. Remove door trim panel.3. Remove two screws retaining seat regulator control
INSTALLATION
> Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Power-Six-Way With Power Recliner > Page 418
Power Seat Switch: Service and RepairPower-Six-Way Without Power Recliner
REMOVAL
1. Remove two screws retaining seat regulator control switch to front seat cushion frame.2. Disconnect harness conn
INSTALLATION
> Sensors and Switches > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch, Seats > Component Information > Service and Repair
Vacuum/Pressure Pump Switch: Service and Repair

REMOVAL
1. Remove lumbar seat control switch from seat by pulling off snap-on seat regulator control switch bezel, then remo
clips while pulling seat control switch from seat regulator control switch bezel.
INSTALLATION
1. Connect harness connector to seat control switch.2. Connect front seat back pad adjusting tube to seat control swit
pad adjusting pump.
3. Install lumbar seat control switch to seat with two retaining screws. Snap seat regulator control switch bezel into p
NOTE: The seat regulator control switch bezel is keyed and can only be installed one way.
4. Check seat for proper operation.

> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Diagrams
Brake Pedal Position Switch

> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations
> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations > Page 429
Parking Brake Release Switch: Description and Operation
Theisautomatic
a vacuumparking
switch.brake release switch:-
- is located on the top of the steering column.
- supplies engine vacuum to the parking brake release vacuum motor in all forward gears.
- vents the parking brake release vacuum motor in PARK, REVERSE and NEUTRAL.
- operates off the shift tube cam which is designed to open and close the parking brake release switch between NEU
Parking Brake Release Switch: Testing and Inspection
Pinpoint Test G1
Pinpoint Test G2 - G3
Parking Brake Release Switch: Service and Repair
REMOVAL
1. Disconnect battery ground cable. 2. Remove lower RH and LH mouldings from instrument panel by pulling up an
INSTALLATION
2-3 Nm (18-26 inch lbs.).
1. Put gear shift lever in NEUTRAL.2. Place parking brake release switch over column mounting bosses and push pa
10. Install RH and LH mouldings on instrument panel.11. Connect battery ground cable.
> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications
Wheel Speed Sensor: Electrical Specifications
Measured using Rotunda EEC-IV 60-Pin Breakout Box
Front and Rear 800-1400 ohms

> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 436
Wheel Speed Sensor: Mechanical Specifications
Front Retaining Bolts 45-53 in.lb
Bracket Bolts 144-228 in.lb
Rear Retaining Bolts 45-53 in.lb

> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front
Wheel Speed Sensor: LocationsFront
Part 1 Of 2
Part 2 Of 2
> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front > Page 439
> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 440
Wheel Speed Sensor: Description and Operation
The anti-lock brake system uses four anti-lock brake sensors to determine the vehicle speed. The anti-lock brake sens
The front anti-lock brake sensors are non-adjustable. The front anti-lock brake sensors and the front anti-lock brake s
The front anti-lock brake sensors are attached to the front wheel spindles and the front anti-lock brake sensor indicato
The rear anti-lock brake sensors are attached to the rear axle housings and the rear anti-lock brake sensor indicators a
> 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 RepairToothed Ring
Front Axle
Transmission and Drivetrain / Drive Axles, Bearings and Joints / Wheel BearingFor front ABS sensor ring Serv
Rear Axle
REMOVAL
1. Remove axle shaft and position on a work bench.
> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page
443

2. Using a thin-blade cold chisel between rear brake anti-lock sensor indicator and axle shaft, strike chisel evenly aro
anti-lock sensor indicator off rear brake anti-lock sensor indicator journal. Discard rear brake anti-lock sensor ind
CAUTION:
Use only a cold chisel, not a screwdriver. Extreme care should be taken not to scratch or nick rear wheel bearing
NOTE: Prior to installation of new rear brake anti-lock sensor indicator, remove any burrs or nicks from journal
INSTALLATION
1. Position Sensing Ring Replacer 206-057 (T94P-20202-A) on Axle Bearing / Seal Plate 205-090 (T75L-1165-B), p
444

2. Place new rear brake anti-lock sensor indicator over Sensing Ring Replacer 206-057 (T94P-20202-A).
3. Insert axle shaft through tool.

4. Place Pinion Bearing Cup Replacer 205-231 (T85T-4616-AH) over hub end of axle shaft.
445

5. Press axle shaft until it bottoms out on axle flange.6. Install axle shaft.
> Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 446
Wheel Speed Sensor: Service and RepairWheel Speed Sensor
Front
Part 1 Of 2
Part 2 Of 2
REMOVAL
1. From inside engine compartment, disconnect front brake anti-lock sensor assembly two-pin connector from wiring
INSTALLATION
5 - 6 Nm (45 - 53 inch lbs.)
1. Install front brake anti-lock sensor into mounting hole in front wheel spindle and install retaining bolt. Tighten to .
Rear
447

REMOVAL
1. Remove the rear seat cushion.2. Disconnect the rear anti-lock brake sensor electrical connector.3. From below the
INSTALLATION
5 - 6 Nm (45 - 53 inch lbs.)
1. Insert rear brake anti-lock sensor into rear wheel disc brake adapter and install retaining bolt. Tighten to .2. Attach
> Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Inform
Coolant Temperature Sensor/Switch (For Computer): Specifications

ECT Sensor ..........................................................................................................................................................................
Coolant Temperature Sensor/Switch (For Computer): Locations

Engine View
> Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) >
Component Information > Specifications > Page 454

Engine View
> Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) >

Engine View
Coolant Temperature Sensor/Switch (For Computer): Description and Operation

ECT
(PCM)The Engine Coolant Temperature sensor ( sensor) changes resistance in response to the engine coolant temperat
NOTE:
In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by t
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature (ECT) Sensor
ECT
16-24 Nm (12-17 lb-ft)1. Partially drain engine cooling system.2. Disconnect battery ground cable.3. Disconnect eng
> Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Inform
Radiator Cooling Fan Temperature Sensor / Switch: Locations

Engine View
The Cylinder Head Temperature Sensor is located on the top LH front of the engine.
NOTE:
> Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Inform
Radiator Cooling Fan Temperature Sensor / Switch: Description and Operation

NOTE:
> Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Description an
Instrument Cluster
Temperature Sensor (Gauge): Description and OperationWith Conventional Instrument Cluster
Engine Coolant Temperature (ECT) Sender
The engine coolant temperature sender is mounted into the engine intake manifold. The signal sent to Engine Coo
> Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Description an
Instrument Cluster > Page 466
Temperature Sensor (Gauge): Description and OperationWith Electronic Instrument Cluster

Coolant Temperature Gauge
The engine coolant temperature gauge has the following features:-

ThisHgauge
meansishigh temperature.
identified by a thermometer symbol.-
- C means low temperature.
- NORM means normal temperature.
-
13,000 ohms 200 ohms 13,000 ohms
This gauge indicates the engine coolant temperature based on an operating resistance range from the engine c
- The number of bars lit increases as the engine warms up (from the lowest bar into the normal operating region
-
It is acceptable under certain driving conditions, such as heavy traffic or stop-and-go driving in hot weather, f
Diagnostic Bars
200 ohms
When the
Diagnostic topontwo
bars thisand bottom
gauge two bars
indicate that appear on the engine
the resistance coolant
of engine temperature
coolant gauge,
temperature a short
sender circuit
is lower thanmay
thebe
o
- When the bottom bar, the thermometer and TEMP displays appear, an open circuit may be present.
Fail Safe Cooling
(CHT)The fail safe cooling system allows limited engine operation in the event of excessive engine temperature.
(124C)
Allthe
Once eight
firstbars of the temperature
temperature threshold gauge will illuminate (H).
is met:-
- The thermometer symbol will flash.
- (MIL)The Malfunction Indicator Lamp (CHECK ENGINE) will illuminate.
- one second five seconds one minute
one minute A tone will sound for every for . If the ignition switch is cycled to OFF and then ON, the duratio
- (PCM)The Powertrain Control Module will disable four of the fuel injectors.
(166C)
Allthe
Once eight bars temperature
second of the temperature gauge
threshold (H) and the thermometer symbol will flash simultaneously.
is met:-
- (MIL)The Malfunction Indicator Lamp (CHECK ENGINE) will remain illuminated.
- one second five secondsA tone will continue to sound for every until the PCM disables all the fuel injectors
Engine Coolant Temperature Sender
is mounted
Engine coolantinto the engine
temperature intake manifold.
sender:-
-
sends a signal to electronic instrument cluster which varies with the resistance of engine coolant temperature s
> Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruis
Recall - Cruise Control Deactivation Switch Inspection
05S28S15Technical Service Bulletin #

> 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 476







Attachment III - Technical Information
Table of Contents

SCDS Identification
The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. S
Note
that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is requ
SCDS Location
In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model yea
^ 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 SC
^
On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of th
- When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to preve
- During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (3
On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of
^
On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash s
FUSED JUMPER HARNESS (FJH) IDENTIFICATION

On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block

The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2.

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.

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 H
-
On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed
^
If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and app
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 vert
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 ins

2.
Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), C
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 S
NOTE:
If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid co
3. Remove the SCDS.
4.
With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As
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
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
^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instru
8.
With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and t

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 Mo
11.
Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided
NOTICE:
Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease di
12.
Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length













Recall - Cruise Control Switch Jumper Harness

Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 506

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
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 OAS

^ 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 Sup
ADDITIONAL LABOR TIME
^
If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to
^
If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covere
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 mod
^ 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
^ Refer to ACESII manual for claims preparation and submission information. Enter claims using Direct Warranty En
Attachment II - Labor and Parts Information
[New!] LABOR ALLOWANCES

[New!] Vehicle Parts Application & Labor Operation Chart
Description of Labor Operations


[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. Ple
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".

Table of Contents
OVERVIEW
This program involves removing the 4W1Z-14A411-BC Fused Jumper Harness (FJH) that was previously installed dur
NOTE:
Do not perform an Interim Repair (SCDS Disconnect) on any of the affected vehicles in this program. Call the Spec
SPEED CONTROL DEACTIVATION SWITCH (SCDS) LOCATION
^
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 connec
^ 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.


UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION
1. Connect the universal fused jumper harness (Part Number 8W7Z-14A411-C) to the SCDS and the vehicle harnes

2.
LEAKING SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT
NOTE:
NOTICE:
2.
NOTICE:
NOTE:
NOTE:

3. Remove the SCDS.
4.
^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the
7.
9.
10.
NOTICE:
Be sure to apply an adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease dir

11.
12. Reconnect the servo connector.
13. Release the vehicle.






Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard
Brake Switch (Cruise Control): RecallsRecall 07V336000: Cruise Control Fire Hazard
COMPONENT: Vehicle Speed Control
POTENTIAL NUMBER OFMODEL/BUILD

MAKE/MODELS: UNITS AFFECTED: 3600000 Ford/Bronco
YEARS: 1993 Ford/Crown Victoria
SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed c
Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 524

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
NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration
> Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection

> 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 530







Table of Contents

SCDS Identification
Note
SCDS Location
^
^



NOTE:

-
^
2.
NOTE:
NOTICE:
NOTICE:

2.
NOTICE:
NOTE:
NOTE:
3. Remove the SCDS.
4.
^ 13 Nm (115 lb-in) - 1994 Capri.
^
8.

10.
11.
NOTICE:
12.













08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness

Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 560

OASIS ACTIVATED?
NOTE:
STOCK VEHICLES
SOLD VEHICLES
^

RELATED DAMAGE
^
^
OWNER REFUNDS
RENTAL VEHICLES
NOTE:



NOTE:
DEALER PRICE

Table of Contents
OVERVIEW
NOTE:
^
NOTE:



2.
NOTE:
NOTICE:
2.
NOTICE:
NOTE:
NOTE:

3. Remove the SCDS.
4.
7.
9.
10.
NOTICE:

11.






NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard
Brake Switch (Cruise Control): All Technical Service BulletinsRecall 07V336000: Cruise Control Fire Hazard

Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 578

> Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 579
Brake Switch (Cruise Control): Specifications

Deactivator Switch ...............................................................................................................................................................
> Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Deactivator Switch
Brake Switch (Cruise Control): Description and OperationDeactivator Switch
The deactivator switch is provided as an additional safety feature. Normally, when the brake pedal is depressed, an elec
> Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Deactivator Switch > Page 582
Brake Switch (Cruise Control): Description and OperationStoplight Switch

When the brake pedal is depressed, an electrical signal from the brake lamp circuit to the speed control servo will deact
> Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service and Repair > Deactivator Switch
Brake Switch (Cruise Control): Service and RepairDeactivator Switch

REMOVAL
1. Disconnect the battery ground cable.2. Disconnect electrical connector from deactivator switch.3. Rotate deactivat
INSTALLATION
1. Pull the plunger out to its full travel.2. Completely depress and hold the brake pedal.3. Install the deactivator switc
> Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service and Repair > Deactivator Switch > Page 585
Brake Switch (Cruise Control): Service and RepairStoplight Switch

REMOVAL
(BPP)1. Disconnect the wire harness at the connector from the Brake Pedal Position switch.
NOTE: Locking tab on connector must be lifted before connector can be removed.
2. Remove the hairpin retainer. Slide the brake pedal position switch, the push rod and the nylon washers and bushin
and remove the brake pedal position switch by sliding the brake pedal position switch up and down.
NOTE:
Since the switch side plate nearest the brake pedal is slotted it is not necessary to remove the brake master cylin
INSTALLATION
1. Position brake pedal position switch so that the U-shaped side is nearest the pedal and directly over and under the
up trapping the master cylinder push rod and black bushing between the switch side plates. Push brake pedal posi
CAUTION: Do not substitute other types of pin retainers, replace only with a production hairpin retainer.
2. Assemble the wire harness connector to the brake pedal position switch.
NOTE:
Brake pedal position switch wire harness must have sufficient length to travel with brake pedal position switch d
3. Check brake pedal position switch for proper operation.

> Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service Precautions
Cruise Control Switch: Service Precautions
WARNING: THE ELECTRICAL CIRCUIT NECESSARY FOR SYSTEM DEPLOYMENT IS POWERED DI

> Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service Precautions > Page 589
Cruise Control Switch: Service and Repair
REMOVAL
one minute1. Disconnect positive battery cable and wait . This is the time required for the air bag diagnostic monito
stored energy.
2. Remove the driver side air bag. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair
3. Remove five screws and upper and lower steering column shrouds from steering column.
4. Rotate steering wheel to gain access to driver side air bag module retaining bolts on rear of steering wheel.
5. Remove two driver side air bag module retaining bolts from rear of steering wheel.
6. Disconnect the speed control actuator switch electrical connector.
7. Remove the four switch clips (two each side) from the speed control actuator switch and remove speed control act
8. Remove the steering wheel.
9. Remove the steering wheel cover.
10. Disconnect the speed control actuator switch electrical connectors.
11. Push the speed control switches out through the front of the steering wheel.
INSTALLATION
1. Install speed control actuator switches.
CAUTION:2. Make sure wires are positioned so that no interference is encountered when installing air bag module
Connect the speed control actuator switch electrical connector.
3. Install the steering wheel cover.
4. Install the steering wheel
5. Install driver side air bag module on steering wheel. See: Restraint Systems/Air Bag Systems/Air Bag/Service and
10-19 N.m (89-124 Lb-In).Install two bolts. Tighten to

> Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Specifications
Vehicle Speed Sensor/Transducer - Cruise Control: Specifications

Vehicle Speed Sensor Retaining Bolt ..................................................................................................................................
> Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Specifications > Page 593
> Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Specifications > Page 594
Vehicle Speed Sensor/Transducer - Cruise Control: Service and Repair

REMOVAL
(VSS)1. Raise vehicle on a hoist.2. Remove bolt retaining Vehicle Speed Sensor mounting clip to transmission.
3. Remove VSS and driven gear from transmission.4. Disconnect electrical connector from vehicle speed sensor.5. R
INSTALLATION
4-6 N.m (36-53 Lb-In). 1. Position driven gear to vehicle speed sensor. Install speedometer driven gear retainer.2. C
> Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications
Oil Pressure Sender: Specifications

TORQUE SPECIFICATIONS
Oil Pressure Sensor ..........................................................................................................................................................
> Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 599
Oil Pressure Sender: Description and Operation
Oil Pressure Switch

Theisoil
threaded
pressureinto the cylinder block.
switch:-
- reacts to the pressure of the engine oil in the lube passage.
- 6 psiis open with low engine oil pressure and closes with oil pressure greater than .
> Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations
Ambient Temperature Sensor / Switch HVAC: Locations

The Ambient Temperature Sensor is located at the center front of vehicle, on front of the upper radiator support.
> Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 604
Ambient Temperature Sensor / Switch HVAC: Description and Operation
The A/C ambient air temperature sensor and bracket:

- is located in front of the A/C condenser core near the center of vehicle.
- contains a thermistor which measures the temperature of outside air.
- sends the temperature reading to the control assembly.
> Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 605
Ambient Temperature Sensor / Switch HVAC: Service and Repair
REMOVAL
1. Disconnect battery ground cable.2. Remove six pushpins and radiator upper sight shield from vehicle.3. Disconnec
NOTE: A/C ambient air temperature sensor and bracket must be removed from mounting bracket by unscrewing
INSTALLATION
1. Install the A/C ambient air temperature sensor and bracket into the wiring shield.2. Connect electrical connector to
> Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair
Blower Motor Switch: Service and Repair

REMOVAL
1. Remove A/C control.2. Remove knob.3. Disconnect electrical connector.4. Remove retaining screw.5. Remove he
INSTALLATION
> Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations
Cabin Temperature Sensor / Switch: Locations

The In Car Temperature Sensor is located behind the top center of the instrument panel.
> Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 612
Cabin Temperature Sensor / Switch: Description and Operation
The in-car temperature sensor:

- is located behind the instrument panel to the right of the EATC assembly.
- contains a thermistor which measures the temperature of the air inside the passenger compartment.
> Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 613
Cabin Temperature Sensor / Switch: Service and Repair

REMOVAL
1. Remove battery ground cable.2. Pull instrument panel moulding away from instrument panel far enough to remov
NOTE: The instrument panel moulding is retained by snap-in tabs.
3. Remove screw and slide automatic temperature control sensor up and out of the instrument panel.
NOTE:
On Grand Marquis, remove four screws retaining climate control assembly and position aside. Access automatic
4. Disconnect the electrical lead and the automatic temperature control sensor hose and elbow from the automatic tem
CAUTION: Use care when removing automatic temperature control sensor hose and elbow to prevent damaging
INSTALLATION
1. Connect the electrical lead and the automatic temperature control sensor hose and elbow to the automatic temperat
> Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > A/C Cycling Switch
Refrigerant Pressure Sensor / Switch: SpecificationsA/C Cycling Switch
Close ....................................................................................................................................................................................
> Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > A/C Cycling Switch > Page 618
Refrigerant Pressure Sensor / Switch: SpecificationsA/C Pressure Cut-Off Switch
Open .....................................................................................................................................................................................
> Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switc
Refrigerant Pressure Sensor / Switch: Description and OperationA/C Pressure Cutoff Switch
An A/C pressure cut-off switch:

- is used on all vehicles to interrupt A/C compressor operation in the event of high system discharge pressures.
- is located on the A/C manifold and tube between the A/C compressor and A/C condenser core.
- is sensitive to discharge pressure.
DUAL FUNCTION
The A/C pressure cut-off switch has the following characteristics:

- The A/C pressure cut-off switch has two sets of contacts. One electrical contact is normally closed.
- 2680-3068 kPa (415-445 psi)When compressor head pressure rises to , the contacts open and the compressor ope
- 1517-1930 kPa (220-280 psi)When head pressure drops to , the contacts again close and allow operation of the A
- 3103 kPa (450 psi)
Shutting down compressor operation prior to the pressure relief valve set point of make sure refrigerant is contai
The switch contains a second set of electrical contacts for high speed fan control which are normally open.
- 1965-2172 kPa (285-315 psi)When discharge line pressure reaches , these contacts close and engage the high spe
- 1724 kPa (250 psi)When pressure drops to approximately , the contacts again open and the high speed fan contro
> Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switc
Refrigerant Pressure Sensor / Switch: Description and OperationA/C Pressure Switch
The A/C cycling switch is mounted on a Schrader valve 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 ste
- This allows the suction pressure inside the suction accumulator/drier to control operation of the A/C cycling swit
- 152-193 kPa (22 to 28 psi)
276-324 kPa (40-47 psi).The electrical switch contacts will open when the suction pressure drops to and close w
- 7-10C (45-50F)
276-324 kPa (40-47 psi) Ambient temperature below approximately , during cold weather seasons, prevents the
- When the A/C cycling switch contacts close, the signal to energize the A/C clutch is sent to the powertrain contro
- The powertrain control module then supplies the voltage to energize the A/C clutch for A/C compressor operation
-
When the A/C cycling switch contacts open, the powertrain control module opens the A/C clutch electrical circui
-
The A/C cycling switch, when functioning properly, will control the A/C evaporator core pressure at a point whe
- This prevents A/C evaporator core icing and the blockage of airflow.
> 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 RepairA/C Cycling Switch
REMOVAL
1. Disconnect the wire connector from the A/C cycling switch.2. Unscrew the A/C cycling switch from the evaporato
INSTALLATION
1. Install a new O-ring seal lubricated with clean Motorcraft YN-12c refrigerant oil or equivalent meeting Ford speci
the suction line fitting.
2. Screw the A/C cycling switch on the suction line fitting. Tighten the A/C cycling switch finger-tight only.3. Conne
> Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch > Page 624
Refrigerant Pressure Sensor / Switch: Service and RepairA/C Pressure Cut-Off Switch
REMOVAL
1. Locate the A/C pressure cut-off switch on the A/C compressor to condenser discharge line.2. Remove the electrica
INSTALLATION
> Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations
Solar Sensor: Locations

The Sun Load Sensor is located on the top RH side of the instrument panel, above the glove box.
> Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 628
Solar Sensor: Description and Operation

The A/C sunload sensor:
- is located on top of the instrument panel on the passenger side.
- contains a photovoltaic cell that is sensitive to light.
-
has some unspecified resistance across the terminals depending upon the amount of light reaching the photovolta
> Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 629
Solar Sensor: Service and Repair

REMOVAL
1. Disconnect battery ground cable.2. Remove instrument panel defroster opening grille and gently pry A/C sunload
INSTALLATION
> Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Electronic Instrument Cluster
Fuel Gauge Sender: Description and OperationElectronic Instrument Cluster

Fuel Level Sender
The fuel level sender, which is part of the fuel pump module, operates in the following manner:-
TheWhen the fuelof
unit consists level is low, resistor
a variable resistance in the fuel
controlled by level sender
the level is low
of an and number
attached of litfuel
float in the bars is minimal (fro
tank.-
- When the fuel level is high, the resistance in the fuel level sender is high and number of lit bars is greater (
> Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Electronic Instrument Cluster > Page 635
Fuel Gauge Sender: Description and OperationConventional Instrument Cluster
Low Fuel Level Warning
NOTE:
The fuel gauge, battery voltage gauge and low fuel level warning switch are calibrated together; therefore, these
When the fuel level falls to approximately 1/8 of a tank, the low fuel indicator will illuminate.
Theislow
designed to reduce
fuel level fuel
warning gauge needle fluctuation caused by fuel motion in the fuel tank.
switch:-
- provides a low fuel warning when fuel gauge reads approximately 1/8 full.
Fuel Pump Module

TheAfuel
variable
pumpresistor
moduleisconsists
controlled by following
of the the level offeatures:-
an attached float in the fuel tank.
-
When fuel level is low, resistance in the fuel level sender is low and movement of the gauge indicator pointer
-
When fuel level is high, the resistance in the fuel level sender is high and movement of the gauge pointer (from
- The fuel level sender (part of fuel pump module) changes resistance according to the level of fuel in the fuel t
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Specifications
Ambient Light Sensor: Specifications

Light sensor Amplifier to Instrument Panel Screws ............................................................................................................
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Specifications > Page 640
Day/Night Sensor/Amplifier
Ambient Light Sensor: Adjustments
If it is necessary to have the head lamps turned on earlier or later than that of the original manufacturer's calibration, th
Ambient Light Sensor: Service and Repair
REMOVAL
1. Remove the instrument panel upper finish panel.2. Remove screw retaining the light sensor amplifier assembly to
INSTALLATION
2-3 N.m (18-26 Lb-In)1. Follow removal procedure in reverse order.2. Tighten sensor retaining screws to .
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations
Backup Lamp Switch: Locations
Transmission View
The Transmission Range Sensor is located at the LH side of the transmission.

> Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 646
Digital Transmission Range Sensor

> Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch (BPP) <--> [Brake Light Switch] > Component Information > Technical Service Bulletin
Position Switch (BPP): > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative
Stoplamps/Shift Interlock - Inoperative
Article No.02-13-6
07/08/02
BRAKES - STOPLAMPS INOPERATIVE - SERVICE REPAIR KIT FOR BRAKE PEDAL POSITION SWITCH
ELECTRICAL - TRANSMISSION SHIFT INTERLOCK INOPERATIVE - SERVICE REPAIR KIT FOR BRAK
LINCOLN:1998-2002 TOWN CAR
ISSUE
The Brake Shift Interlock may be inoperative on some vehicles, not allowing the operator to move the shift lever from
ACTION
Restore Brake Pedal Position Switch operation by installing an updated electrical connector and pigtail.
Refer to the following Service procedure for details.
Parts Block
021306A Replace Brake Pedal 0.4 Hr.
Position Switch ElectricalConnector

DEALER CODING CONDITION
BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
1. Verify the condition.
2. Remove LH instrument panel insulator. Refer to Workshop Manual Section 501-05.
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch (BPP) <--> [Brake Light Switch] > Component Information > Technical
Service Bulletins > Customer Interest for Brake Pedal Position Switch (BPP): > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 655

3.
Inspect the Brake Pedal Position Switch electrical connector (2000/2001 - C2002: 2002 - C278) for deformation.
4. If no deformation is found, refer to Workshop Manual, Sections 307-05 & 417-01, for normal diagnostic informa
5. If deformation is found, continue with the following procedure.
6. Disconnect the battery ground cable.
7. Disconnect the Brake Pedal Position Switch electrical connector.
8. Remove the deformed connector by cutting off 4 inches of wire from the harness.
9. Strip approximately 1/4" from the remaining harness and twist the end of each wire.
10. Obtain the repair kit part number 2W1Z-14A411-AAA.
11. The repair kit pigtail wiring comes in 1 piece with connectors.
12. Strip approximately 1/4" of insulation from the repair pigtail and twist the end of each wire.
13. Since the switch is polarity sensitive, match evenly the wire color (LG light green to LG, LG/RD light green with
14. Use crimp connectors that are found in the repair kit.
15. Evenly position the crimp connectors over the wire repair.
16. To crimp the connectors, use the proper wire crimp tool.
17. Use a heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink.
18. Reconnect the Brake Pedal Position Switch.
19. Replace the LH instrument panel insulator.
20. Reconnect battery ground cable.
21. Test and verify the Brake Pedal Position Switch operates properly.
for Brake Pedal Position Switch (BPP): > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative
Article No.02-13-6
07/08/02
ISSUE
ACTION
Parts Block

BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
Service Bulletins > All Technical Service Bulletins for Brake Pedal Position Switch (BPP): > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 661

3.
Brake Pedal Position Switch (BPP): Description and Operation

(BPP)The Brake Pedal Position switch provides power to the stoplamps and signals various other systems, including:
- anti-lock brake control module
- (PCM)Powertrain Control Module
- shift lock actuator
- speed control servo
(15 A)
Power is provided to the BPP switch through Fuse 1 . This fuse is hot at all times. With the BPP switch closed, power i
Brake Pedal Position Switch (BPP): Service and Repair

REMOVAL
Fig. 3 Stop light switch replacement
2. Remove the hairpin retainer and slide the BPP switch, the push rod and the nylon washers and bushing away from
BPP switch by sliding the BPP switch up/down as required to remove.
Service Bulletins > Page 664

NOTE:
Since the BPP switch side plate nearest the brake pedal is slotted, it is not necessary to remove the brake master
INSTALLATION
1. Position BPP switch so that the U-shaped side is nearest the brake pedal and directly over or under the pin. Then s
trapping the master cylinder push rod and black bushing between the stoplight switch side plates. Push BPP switc
CAUTION: Do not substitute other types of pin retainers. Replace only with a production hairpin retainer. Com
2. Assemble the wire harness connector to the BPP switch.
NOTE:
BPP switch wire harness must have sufficient length to travel with BPP switch during full stroke of brake pedal
3. Check BPP switch for proper operation.

> Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions
Hazard Warning Switch: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 677
Hazard Warning Switch: Connector Views
Multi_function Switch
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 678
Multi_function Switch - Schematic - Lamp Portion Of Multi-function Switch

> Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 679
Hazard Warning Switch: Description and Operation

The hazard flasher switch (part of multi-function switch) is located on the top of the steering column forward of the ste
- The switch will cycle smoothly from OFF to ON by pressing and releasing the switch top.
- The switch will produce an audible click when it toggles from one position to another.
- The switch will extend markedly further above the column when the switch is ON than it does when it is OFF.
When the hazard switch is in the ON position, the four turn signal lamps will flash. Also, the two turn indicators in the
> 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

NOTE: (NGS)
(SBDS) The Rotunda New Generation Star Tester 007-00500 or equivalent scan tool must be used to perform diagnos
INSPECTION AND VERIFICATION
1. Verify the customer's concern by operating the ignition switch and multi-function switch to duplicate the condition
Damaged-multi-function switch.
Mechanical
- Damaged ignition switch.
Circuitry
Electrical - open/shorted.
-
Open4 (15A)
Junction Panel Fuse:-
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
- Circuit breaker 14 (20A)
-
OpenIGNSW
Power(50A)
Distribution Box Fuse-
- STR/ALT (30A).
(DLC)3. If inspection reveals an obvious concern that is readily serviced, correct the concern before continuing with
DATA LINK DIAGNOSTICS (DTC) test. If the scan tool responds with NO RESPONSE/NOT EQUIPPED for
See: Pinpoint Tests/Test A: No Communication With Lighting Control Module
If the DATA LINK DIAGNOSTICS test is passed for the lighting control module, retrieve continuous DTCs and
5. If self test is passed and no DTCs are retrieved go to the Symptom Chart to continue diagnostics.
See: Symptom Related Diagnostic Procedures
(LCM)6. If DTCs are retrieved, go to the Lighting Control Module Diagnostic Trouble Code (DTC) Index to contin
See: Lighting and Horns/Headlamp/Testing and Inspection/Component Tests and General Diagnostics/Diagnostic Tro
7. If the lighting control module cannot be accessed by the scan tool, go to Pinpoint Test A.
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 682
Hazard Warning Switch: Initial Inspection and Diagnostic Overview

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).
Hazard Warning Switch: Diagnostic Trouble Code Descriptions

Part 1 Of 3
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis >
Page 684

Part 2 Of 3
Part 3 Of 3
Part 1 Of 2
Page 685

Part 2 Of 2
Hazard Warning Switch: Symptom Related Diagnostic Procedures
Part 1 Of 2
Part 2 Of 2
Hazard Warning Switch: Testing and Inspection
Flow of Diagnosis
NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).
Initial Inspection and Diagnostic Overview

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
Page 688

-
IGNSW
Open Power(50A)
- STR/ALT (30A).
Page 689

Part 1 Of 3
Part 2 Of 3
Part 3 Of 3
Page 690

Part 1 Of 2
Part 2 Of 2
Part 1 Of 2
Page 691

Part 2 Of 2
Page 692

Page 693

Pinpoint Test B1 - B4
Page 694

Page 695

Pinpoint Test G1
Page 696

Multi-Function Switch Terminals-Component Side

Page 697

Multifunction Switch Continuity Test
Multi-Function Switch Function Test

Page 698

Multi_function Switch - Component Testing Procedure
Multi-Function Switch - Terminals
Page 699

> Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 700
Hazard Warning Switch: Service and Repair
REMOVAL
1. Disconnect battery ground cable. 2. Remove ignition switch lock cylinder.3. Remove shroud screws and remove u
steering column lock cylinder housing.
5. Disconnect the two electrical connectors.
INSTALLATION
1. Connect two electrical connectors to full engagement.2. Align multi-function switch mounting holes with correspo
2-3 Nm (18-26 inch lbs.).making sure to start screws in the previously tapped holes. Tighten to
3. Install upper steering column shroud and lower steering column shroud with screws.4. Install ignition switch lock
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions
Headlamp Dimmer Switch: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 713
Headlamp Dimmer Switch: Connector Views
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 714

> Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 715
Headlamp Dimmer Switch: Description and Operation

MULTI-FUNCTION SWITCH
Theturn signal.
multi-function switch, which is mounted to the steering column lock cylinder housing, provides electrical sw
- hazard warning.
- cornering lamps.
- headlamp dimmer.
- headlamp flash-to-pass.
- windshield washer/wiper The intermittent wiper control switch, located in the knob at the end of the turn sign
NORMAL OPERATION
TheSelect high dimmer

headlamp beam byswitch
moving thethe
and turn signal leverfeature,
flash-to-pass away from the driverby
also operated to the
the turn
stop.signal lever, operate as follo
- Release the lever to maintain high beams.
- Select low beam by moving the turn signal lever toward driver from high beam position.
- Release the lever to maintain low beams.
FLASH-TO-PASS
- Pull the lever gently toward driver to operate flash-to-pass feature.
NOTE:
Excessive force used to hold the turn signal lever in the flash-to-pass function followed by quick release may re
- Release lever to return to low beam position.

- Using the flash-to-pass feature without the headlamps on will turn on the high beams until the turn signal leve
- Using the flash-to-pass feature with the headlamps on will keep the low and high beams on until the turn sign
> 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

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 718
Headlamp Dimmer Switch: Initial Inspection and Diagnostic Overview

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).
Headlamp Dimmer Switch: Diagnostic Trouble Code Descriptions

Part 1 Of 3
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis >
Page 720

Part 2 Of 3
Part 3 Of 3
Part 1 Of 2
Page 721

Part 2 Of 2
Headlamp Dimmer Switch: Symptom Related Diagnostic Procedures

Headlamp Dimmer Switch: Testing and Inspection
Flow of Diagnosis
NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
Page 724

-
IGNSW
Open Power(50A)
- STR/ALT (30A).
Page 725

Part 1 Of 3
Part 2 Of 3
Part 3 Of 3
Page 726

Part 1 Of 2
Part 2 Of 2
Page 727

Page 728

Page 729

Page 730

Page 731

Pinpoint Test G1
Page 732


Page 733


Page 734

Page 735

> Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 736
Headlamp Dimmer Switch: Service and Repair
REMOVAL
1. Disconnect battery ground cable. 2. Tilt the steering column to the lowest position and remove the tilt wheel handl
INSTALLATION
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions
Headlamp Switch: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions >
Page 741

Page 742

System Diagrams
Page 743

Grounds Diagrams
Page 744

ELECTRICAL SYMBOLS
Electrical Symbols
Page 745

Electrical Symbols
VACUUM SYMBOLS
Page 746

Vacuum Symbols

BK
BL
BR
Page 747

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 748
Headlamp Switch: Connector Views
Main Light Switch (C262)

Page 749

> Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 750
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 751
Headlamp Switch: Description and Operation
-
Rotating the headlamp switch clockwise to the PARK position (first detent) supplies a signal to the lighting contr
-
Rotating the headlamp switch clockwise to the HEAD position (second detent) supplies a signal to the lighting co
- Rotating the headlamp switch counterclockwise operates the autolamp and time delay systems.
- Pressing in on the headlamp switch operates the dome lights.
Panel Dim Switch The panel dim switch is located above the headlamp switch and controls the instrument panel
Headlamps ON Warning Chime If the headlamp switch is left in either the PARK or HEAD position, and the d
Headlamp Switch: Testing and Inspection
Main Light Switch - Component Testing Procedure

Main Light Switch - Terminal Locations

Headlamp Dimmer Switch - Terminal Locations

Headlamp Switch: Service and Repair
REMOVAL
1. Disconnect battery ground cable.2. Remove light switch knob from headlamp switch by grasping knob and pulling
INSTALLATION
3 N.m (26 Lb-In)1. Follow removal procedure in reverse order.2. Tighten switch retaining nut to .
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation
Horn Switch: Description and Operation

The horn blow switch is underneath driver side air bag module in the steering wheel.
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation > Page 759
Horn Switch: Service and Repair

REMOVAL
WARNING: ALWAYS WEAR SAFETY GLASSES WHEN SERVICING AN AIR BAG VEHICLE AND WHE
one minute1. Center front wheels to the straight-ahead position.2. Disconnect battery ground cable.3. Disconnect po
WARNING: THE ELECTRICAL CIRCUIT NECESSARY FOR AIR BAG SYSTEM DEPLOYMENT IS
4. Remove driver side air bag module.5. Disconnect two ground wires (BK) from upper horn switch plates. Disconne
(R) head retaining bolts and remove horn switch plates.
INSTALLATION
4-5 N.m (36-44 Lb-In)1. Follow removal procedure in reverse order.2. Tighten retaining bolts to .
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Service and Repair
Interior Light Switch: Service and Repair
REMOVAL
1. Remove front door trim panel and water-shield.2. Remove screw retaining lamp switch to front door latch.3. Disco
INSTALLATION
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Locations
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Diagram Information and In
Multifunction Switch: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Diagram
Information and Instructions > Page 768


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
Multifunction Switch: Connector Views

> Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Page 777
Multifunction Switch: Description and Operation

Theturn signal.
- hazard warning.
- cornering lamps.
- headlamp dimmer.
NORMAL OPERATION
TheTurn
turn the ignition
signal switchswitch to RUN. into the multi-function switch. Turn signals operate in the following manne
is incorporated
- Move turn signal switch lever to end-of-travel position to indicate a normal full turn.
- The lever remains in position without effort until turn is completed.
- The turn indicator cancel cam then automatically cancels the turn signal.
LANE CHANGE FEATURE
Movethe
Operate and hold
lane the turn
change signalaslever
system to the first stop position when changing lanes.
follows:-
- Releasing the lever returns it to its normal position when the maneuver is over.
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Testing and Inspection > Flow of Diagn
Multifunction Switch: Flow of Diagnosis

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).
See: Lighting and Horns/Turn Signals/Testing and Inspection/Diagnostic Trouble Code Descriptions/LCM Diagnostic
Multifunction Switch: Initial Inspection and Diagnostic Overview

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).
Multifunction Switch: Diagnostic Trouble Code Descriptions
Part 1 Of 3
Part 2 Of 3
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Testing and Inspection >
Flow of Diagnosis > Page 782

Part 3 Of 3
Multifunction Switch: Symptom Related Diagnostic Procedures

Multifunction Switch: Testing and Inspection
Flow of Diagnosis
NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).

NOTE: (NGS)
Damaged multi-function switch.
-Mechanical
Damaged-ignition switch.
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
- Open Power Distribution Box Fuse

- IGNSW (50A)
- STR/ALT (30A).
Part 1 Of 3

Part 2 Of 3
Part 3 Of 3


Pinpoint Test G1


Multi-Function Switch Funtion Test




Part 1 Of 2
Part 2 Of 2
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Testing and Inspection > Page 793
Multifunction Switch: Service and Repair
REMOVAL
INSTALLATION
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Updated R
Article No.01-19-4
10/01/01
PARTS BLOCK

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > T
Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms
Air Flow Meter/Sensor: All Technical Service BulletinsEngine - Lean Driveability Symptoms
Article No.98-23-10
11/23/98
MASS AIR FLOW (MAF) - SENSORCONTAMINATION - SERVICE TIP
FORD:1990-97 THUNDERBIRD1990-99 MUSTANG, TAURUS SHO1991-99 CROWN VICTORIA, ESCORT, TAU
LINCOLN-MERCURY:1990-97 COUGAR1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, T
LIGHT TRUCK: 1990 BRONCO II1990-97 AEROSTAR1990-99 RANGER1991-99 EXPLORER1994-96 BRONCO
ACTIONFollow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is
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
ISSUEThis TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may o
If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provid
One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by t
> 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 for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms >
Page 808

voltage at idle.
NOTE
THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE
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)
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)
^ 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 TER
Page 809

1.
Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO sho
NOTE
REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT H
NOTE
2.
On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LON
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
4.
If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the
NOTE
BAROTO
DUE ISINCREASINGLY
UPDATED ONLYSTRINGENT
WHEN THEEMISSION/OBDII
VEHICLE IS AT HIGH
REQUIREMENTS,
THROTTLE OPENINGS.
IT IS POSSIBLE
THEREFORE,
FOR SOME
A VV
After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehic
OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206
Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms
Air Flow Meter/Sensor: Customer InterestEngine - Lean Driveability Symptoms
Article No.98-23-10
11/23/98
SERVICE TIP

Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 815

voltage at idle.
NOTE
Symptoms
^ Lack of Power
^ Buck/Jerk
OBDII DTCs
OBDI DTCs
NOTE:

1.
NOTE
NOTE
BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A V
2.
3.
4.
NOTE
DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME V
Air Flow Meter/Sensor: Specifications
MAF Sensor to Bracket Bolts ..............................................................................................................................................

Air Flow Meter/Sensor: Locations

Engine View
The Mass Air Flow Sensor is located at the LH front of the engine compartment, behind air cleaner assembly.
Mass Air Flow Sensor

Air Flow Meter/Sensor: Description and Operation
Mass Air Flow (MAF) Sensor
MAFThe Mass Air Flow sensor ( sensor):

- (ACL)is mounted on the corner of the engine Air Cleaner .
- uses a hot wire sensing element to measure the amount of air entering the engine; air passing over the hot wire ca
- (PCM)
sends out an analog voltage signal to the Powertrain Control Module to determine the intake air mass. The PCM
The mass air flow sensor hot wire sensing element and housing are calibrated as a unit and must be serviced as a compl
Air Flow Meter/Sensor: Service and Repair

CAUTION:
MAF The mass air flow hot wire sensing element and housing are calibrated as a unit and must be serviced as a compl
4.7-5.0 Nm (42-44 lb in)1. Disconnect battery ground cable.2. Disconnect engine control sensor wiring from mass a
1.4-2.5 Nm (13-22 lb in)clamps to .
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information >
Camshaft Position Sensor: Specifications

Camshaft Position Sensor to Engine Front Cover ...............................................................................................................
Camshaft Position Sensor: Locations

The Camshaft Position Sensor is located at the LH front of the engine, below the left ignition coil.
Camshaft Position Sensor: Description and Operation

CMPThe Camshaft Position sensor ( sensor) is a variable-reluctance sensor which is triggered by the high-point mark o
Camshaft Position Sensor: Service and Repair
REMOVAL
CMP
1. Disconnect battery ground cable.2. Disconnect engine control sensor wiring from Camshaft Position sensor ( senso
INSTALLATION
1. Make sure camshaft position sensor mounting surface is clean and that camshaft position sensor O-ring is in prope
sensor.
8-12 Nm (71-106 lb in)2. Position camshaft position sensor and install retaining screw. Tighten to .
CAUTION: Do not overtighten camshaft position sensor retaining screw or damage to camshaft position sensor
3. Connect engine control sensor wiring to camshaft position sensor.4. Connect battery ground cable.
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) >
Specifications

ECT Sensor ..........................................................................................................................................................................

Engine View
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (
For Computer) > Component Information > Specifications > Page 832

Engine View
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (
For Computer) > Component Information > Specifications > Page 833

Engine View

ECT
NOTE:
ECT
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information
Crankshaft Position Sensor: Specifications

Crankshaft Position Sensor Screw .......................................................................................................................................
Crankshaft Position Sensor: Locations

Engine View
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor >

The Crankshaft Position Sensor is located at the lower RH front of the engine.
Crankshaft Position Sensor: Description and Operation
NOTE: 10 degrees 2 degrees (BTDC) Initial engine ignition timing is set at Before Top Dead Center and is not adj
CKP
The Crankshaft Position sensor ( sensor) is a variable reluctance sensor triggered by a 36-minus-1 tooth trigger pulse w
The sine wave type signal generated from the crankshaft position sensor provides two types of information:
- 10-degreeposition of the crankshaft in increments.
- (rpm)crankshaft speed .
- (PCM)The Powertrain Control Module uses this information to determine ignition coil turn ON and turn OFF tim
Crankshaft Position Sensor: Service and Repair
Crankshaft Position (CKP) Sensor
REMOVAL
CKP
1. Disconnect battery ground cable.2. Remove serpentine drive belt.3. Raise vehicle on a hoist.4. Disconnect engine
INSTALLATION
1. Make sure crankshaft position sensor mounting surface is clean and that new crankshaft position sensor O-ring is i
position sensor.
8-12 Nm (71-106 lb in).2. Position crankshaft position sensor and install retaining screw. Tighten to
CAUTION: Do not overtighten crankshaft position sensor retaining screw or damage to sensor may occur.
3. Install A/C compressor. Evacuate and recharge A/C system.4. Properly route engine control sensor wiring and con
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information
Fuel Tank Pressure Sensor: Locations

The Fuel Tank Pressure Sensor is located on the upper tank assembly.
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information
Fuel Tank Pressure Sensor: Service and Repair

REMOVAL
1. Remove the fuel tank.2. Apply downward pressure while turning counterclockwise.3. Remove the fuel tank pressu
INSTALLATION
1. Follow the removal procedure in reverse order.2. Leak test.3. Perform Evaporative Emission Running Loss Monit
Systems/Evaporative Emissions System/Testing and Inspection
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Informa
Intake Air Temperature Sensor: Locations

Engine View
The Intake Air Temperature Sensor is located at the LH front of the engine compartment.
Intake Air Temperature Sensor: Description and Operation

IAT
(PCM)
The Intake Air Temperature sensor ( sensor) changes resistance in response to intake air temperature. The IAT sensor r
Intake Air Temperature Sensor: Service and Repair

NOTE: IAT
The Intake Air Temperature sensor ( sensor) is located in the engine air cleaner cover. When installing, use care not to
90 degrees
1. Disconnect battery ground cable.2. Disconnect engine control sensor wiring from intake air temperature sensor.3.
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technica
Engine Controls - Driveability Diagnosis
Emissions/Engine Controls - Driveability Diagnosis
Article No.01-9-7
05/14/01
DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERV
FORD:1994-1997 THUNDERBIRD1994-2001 MUSTANG1995-2001 CROWN VICTORIA1996-1997 PROBE1996-
LINCOLN:1995-2001 CONTINENTAL, TOWN CAR1996-1998 MARK VIII2000-2001 LS1998-2001 NAVIGATOR
MERCURY:1994-1997 COUGAR1995-2001 GRAND MARQUIS1996-1999 TRACER1996-2000 MYSTIQUE1996-
ISSUEThis article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalys
ACTIONUse the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System
OTHER APPLICABLE ARTICLES: 98-23-10WARRANTY STATUS: INFORMATION ONLYOASIS CODES: 623
Information
^ A. Description of Terms and Acronyms
^ B. HO2S Location Diagrams
^ C. Heated Oxygen Sensor (HO2S) Monitor
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component
Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 856

^ 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)

^ 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 i
C. Heated Oxygen Sensor (HO2S) Monitor
C1.) Heated Oxygen Sensor (HO2S) Monitor - Information

The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration tha
The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean
^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for prope
^
Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are check
^
A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and outpu
^
An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change
^ 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





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
Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst mon
Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of fro
^
Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive c
NOTE
THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS RE
The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor
The Catalyst Monitor DTCs can be categorized as follows:

^
Catalyst system efficiency below threshold (Bank1) - P0420
^
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 use
^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or le
^
A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel T
^
When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMB
The Fuel System Monitor DTCs can be categorized as follows:
^ Fuel Delivery Error - P0148

^ 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)

E2.) Fuel System Monitor - Diagnostic Trouble Codes
F. Diagnostic Service Tips
1. Always reset KAM after performing a repair:
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 certa
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 bot
(P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152).
To further clarify this, see the more detailed scenario as follows:

After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfun
A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 cir

In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern wit
NOTE
THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EX

4.
View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configuration
In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice t
5.
H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is
Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unbu
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
2.
Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-
F3.) Tips Related to Catalyst Efficiency Monitor
1. Determining catalyst efficiency/switch ratio:


The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an ef
NOTE
IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPL
2.
Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors
3.
Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a

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-retur
2.
DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle
3.
Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type
a.
Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (1
Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brak
b.
Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/
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.
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 partiall
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 id
Oxygen Sensor: Specifications

HO2S to Converter ..............................................................................................................................................................
Oxygen Sensor: Locations
H02S Location
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagram
Instructions
Oxygen Sensor: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
Oxygen Sensor: Connector Views
Ford does not provide connector views for this vehicle.

Oxygen Sensor: Description and Operation
(HO2S)The Heated Oxygen Sensors are located in the dual converter Y pipe below the exhaust manifolds and below t
-
TheAheated
low voltage
oxygenindicates too much
sensors react with oxygen or a in
the oxygen lean
thecondition.
exhaust gases and generate a voltage based on this reactio
- A high voltage indicates not enough oxygen or a rich condition.
Oxygen Sensor: Service and Repair

SPECIAL SERVICE TOOL(S) REQUIRED
Description
- Oxygen Sensor Wrench
Tool Number
- 303-476 (T94P-9472-A)
1. Disconnect battery ground cable.2. Disconnect heated oxygen sensors from engine control sensor wiring.
NOTE: (HO2S) Four Heated Oxygen Sensors are used for the engine control system. They are located in the du
3. Raise vehicle on hoist.4. Remove heated oxygen sensors from dual converter Y pipe using Oxygen Sensor Wrench
NOTE: If excessive force is needed to remove heated oxygen sensors, lubricate heated oxygen sensors with pen
36-46 Nm (27-33 lb-ft)5. To install, reverse removal procedure. Tighten heated oxygen sensors to .
Oxygen Sensor Wrench

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Componen
Pressure Feedback Exhaust Sensor: Specifications
Differential Pressure Transducer Bolts ................................................................................................................................

890
Pressure Feedback Exhaust Sensor: Locations

Engine View
The Differential Pressure Feedback EGR Sensor is located at the center rear of the engine, near RH side of intake mani
891
Pressure Feedback Exhaust Sensor: Service and Repair
8-12 Nm (71-106 lb in)1. Disconnect fuel charging wiring from EGR backpressure transducer.2. Disconnect EGR ba
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information >
Throttle Position Sensor: Specifications

Throttle Position Sensor Screws ..........................................................................................................................................
Throttle Position Sensor: Locations

The Throttle Position Sensor is located on the top center rear of the engine, LH side of the throttle body.
Throttle Position Sensor: Description and Operation
TPThe Throttle Position sensor ( sensor) is:

- (PCM)a potentiometer that provides a signal to the Powertrain Control Module directly proportional to the throt
- mounted to the throttle body, connected to the throttle plate shaft.
Throttle Position Sensor: Adjustments

TPThe Throttle Position sensor ( sensor) cannot be adjusted and must be replaced if out of specification.
Throttle Position Sensor: Service and Repair
Throttle Position Sensor
TP
2.8-3.8 Nm (25-33 lb in)1. Disconnect battery ground cable.2. Disconnect Throttle Position sensor ( sensor) from en
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range (TR) Sensor <--> [Transm
> Component Information > Locations
Digital Transmission Range (TR) Sensor: Locations
Transmission View

> Component Information > Locations > Page 902

Digital Transmission Range (TR) Sensor: Adjustments
1. Install Digital TR sensor on manual control lever and two shims, then loosely install bolts.2. Position manual cont
NOTE: PARK is the last detent when the manual control lever is full forward. Return two detents toward output
(TR)3. Insert Digital Transmission Range Sensor Alignment Tool 307-351 (T97L-7001O-A) into slots. Align all thr
range sensor with three tabs on tool.
7 - 10 Nm (62 - 88 inch lbs.).
19 - 26 Nm (14 - 19 ft. lbs.)
4. Tighten digital TR sensor bolts to and remove tool.5. Connect electrical harness to digital transmission range sens
Digital Transmission Range (TR) Sensor: Service and Repair
REMOVAL
(TR)1. Position manual control lever in the neutral position.2. Disconnect battery ground cable.3. Raise vehicle on h
7. Remove digital transmission range sensor.
INSTALLATION
1. Install digital transmission range. sensor and loosely install two retaining bolts.
(TR)
7 - 10 Nm (62-88 inch lbs.)
19 - 26 Nm (14 - 19 ft. lbs.)
2. Align Digital TR sensor slots using Digital Transmission Range Sensor Alignment Tool 307-351 (T97L-70010-A
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Lo
Vehicle Speed Sensor: Locations
Transmission View
The Vehicle Speed Sensor is located at the LH rear of the transmission.

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Di
Instructions
Vehicle Speed Sensor: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Di
Vehicle Speed Sensor: Description and Operation
Vehicle Speed Sensor (VSS)
(VSS) (PCM)
The Vehicle Speed Sensor is a magnetic pickup that sends a signal to the Powertrain Control Module . This VSS signa
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Info


Engine View
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > T
Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms
Article No.98-23-10
11/23/98
SERVICE TIP

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component

voltage at idle.
NOTE
Symptoms
^ Lack of Power
^ Buck/Jerk
OBDII DTCs
OBDI DTCs
NOTE:

1.
NOTE
NOTE
2.
3.
4.
NOTE
Article No.98-23-10
11/23/98
SERVICE TIP

Page 941

voltage at idle.
NOTE
Symptoms
^ Lack of Power
^ Buck/Jerk
OBDII DTCs
OBDI DTCs
NOTE:
Page 942

1.
NOTE
NOTE
2.
3.
4.
NOTE
BAROTO
DUE ISINCREASINGLY
VEHICLE IS AT HIGH
REQUIREMENTS,
THROTTLE OPENINGS.
IT IS POSSIBLE
THEREFORE,
FOR SOME
A VV


Engine View


- (PCM)

CAUTION:
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information >
Fuel Temperature Sensor: Service and Repair

WARNING:
-
EYE PROTECTION IS REQUIRED TO BE WORN DURING REMOVAL AND INSTALLATION OF F
-
FUEL SUPPLY TUBES ARE ALWAYS PRESSURIZED. WHEN SERVICING FUEL-RELATED COMP
REMOVAL AND INSTALLATION
1. Perform Fuel Charging System Pre-Service and Fuel Pressure Release procedures.2. Disconnect fuel charging wir
-M2C153-G.
4. Remove the fuel injection supply manifold temperature sensors from fuel injection supply manifold using a backu
22-28 Nm (17-20 lb-ft)fuel injection supply manifold temperature sensors in by hand. Tighten sensors to .
6. Perform Fuel Charging System, Post-Service procedures.
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information
Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement
99B03Technical Service Bulletin #
Campaign - Inertia Switch Bracket Replacement

99B03
OWNER NOTIFICATION PROGRAM
Certain 1998 and 1999 Crown Victoria/Grand Marquis - Inertia Switch
Original - March, 1999
Dealer Letter
Administrative
Attachment I^ Information
^ Refund Codes
Labor Allowances
Attachment II^
^ Parts Ordering Information
TechnicalIII^
Attachment Information
Customer Notification Letter
Supplement # 1 - May, 1999
1998-99 Crown Victoria/Grand Marquis - Inertia Switch
IMPORTANT RECALL/SPECIAL PROGRAM INFORMATION

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement >
Page 959

Page 960

OASISYou must use OASIS to determine if a vehicle is eligible for this program.
PLEASE NOTECorrect all vehicles in stock before delivery.
PROMPTLY CORRECT
^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC).
^ Other eligible vehicles which are brought to your dealership.
DEALER-OWNER CONTACTImmediately contact any affected owner whose name is not on the list. Give owner a co
Arrange with the owner for a service date.
CLAIMSEnter claims using DWE. See ACESII Manual, Sections 5 & 6.

OWNER REFUNDSSee ACESII Manual, Section 3-59 for submission procedures.
For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency rep
Program Code - 99B03
Misc. Expense - REFUND
Misc. Expense - ADMIN
Misc. Expense - 0.2 Hr.
Page 961

LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts will not be direct shipped for this recall. Order your parts requirements through normal processing channels.
Inertia Bracket Kit: XW7Z-9D379-AA
CLAIMS PREPARATION
-- Entering using DWE
-- Use code information shown below:
^ Program Code - 99B03
^ Labor Operation - See above
See Sections 5 & 6 of the ACESII manual for detailed instructions.

SERVICE PROCEDURE
1. Open trunk.
Page 962

2. Remove carpet pushpins from left inner quarter panel. See Figure 1.
3. Pull carpet away from left inner quarter panel.

4. Remove wiring harness routing pushpins, then position wiring harnesses away from inner quarter panel reinforce
Page 963

5.
NOTE:Remove inertia switch cover-to-bracket retaining screws. See Figure 2. Retain screws for installation pur
6. Position inertia switch assembly away from inner quarter panel reinforcement. DO NOT disconnect inertia switch
7. Remove and discard inertia switch bracket and J-nut. Retain screw for installation purposes.
8. Measure, mark and drill bottom anti-rotation hole as follows:
^ Locate square-cut hole in inner quarter panel reinforcement. See Figure 3.

^ From corner of hole shown in Figure 3, measure directly back 5 mm. Place a temporary mark at this location.
^ From the temporary mark, measure directly down 10 mm. See Figure 3. Center punch this new location.
^ Using a 25/64 inch drill bit, drill hole at center punched location.
Page 964

9. Position new inertia switch bracket on inner quarter panel reinforcement as shown in Figure 4.
10. Mark inertia switch bracket mounting bolt locations. See Figure 4. Center punch these locations.
11. Remove inertia switch bracket.

Page 965

12. Using a 25/64 inch drill bit, drill a hole at each inertia switch mounting bolt location. See Figure 5.
13. Clean all metal shavings from luggage compartment.
14. Install new inertia switch bracket with mounting tab on top and elongated hole facing down. See Figure 6. Tighte
15. Using original screws, install inertia switch assembly on bracket.Tighten screws to 3 Nm (2.2 lb-ft).
16. Install wiring harness routing pushpins.
17. Press reset button on inertia switch. Make sure switch is set properly.
18. Reposition carpet back on left inner quarter panel.
19. Install carpet pushpins.
20. Close trunk.

Page 966

Page 967

Page 968

Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement

99B03
Dealer Letter
Administrative
^ Refund Codes
Labor Allowances
Attachment II^
TechnicalIII^

Component Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch
Bracket Replacement > Page 974


PROMPTLY CORRECT


LABOR ALLOWANCES
PARTS REQUIREMENTS
CLAIMS PREPARATION

SERVICE PROCEDURE
1. Open trunk.



5.




20. Close trunk.




984
Inertia Fuel Shutoff Switch: Locations
The inertia fuel shutoff switch in mounted on the left side of the luggage compartment.
and Instructions
Inertia Fuel Shutoff Switch: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
Component Information > Diagrams > Diagram Information and Instructions > Page 987


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
Inertia Fuel Shutoff Switch: Description and Operation
Inertia Fuel Shutoff (IFS) Switch
(IFS)
The Inertia Fuel Shutoff switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to
The IFS consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the m
Inertia Fuel Shutoff Switch: Service and Repair
REMOVAL
IFS
1. Open luggage compartment door.2. Remove screw retaining Inertia Fuel Shutoff switch ( switch).3. Disconnect w
INSTALLATION
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information >




TP
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications



REMOVAL
CMP
INSTALLATION
sensor.
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications


Engine View
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information
> Specifications > Page 1014

CKP
REMOVAL
CKP
INSTALLATION
position sensor.
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Inform
Locks - Lock Service Packages Available
Ignition Switch Lock Cylinder: Technical Service BulletinsLocks - Lock Service Packages Available
Article No.99-24-2
11/29/99
LOCKS - REPLACE AND/OR REPAIR ANY LOCKCOMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS
FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS1997 THUNDERBIRD1996 BRONCO, F-150-350 S
LINCOLN:1996-2000 TOWN CAR1997-1998 MARK VIII1997-2000 CONTINENTAL1998-2000 NAVIGATOR
MERCURY:1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR1997-2000 MOUNTAINEER

> 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 1022


This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever K
ISSUEThe current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair pract
ACTIONLock service packages have been released that contain all the necessary components to re-pin a new lock cyli
NOTE
MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS O

^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Sectio
^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 50
Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for co
Determine the matching key cut depth at each key station (any of the following three methods may be used to determin
^
Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling deale
Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can b
^
Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet conta
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
Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinde
For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-304
A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This specia
NOTE
THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK C

A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle i
NOTE
THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY L

E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABE
NOTE
SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS A
1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need se
NOTE
1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES.
OTHER APPLICABLE ARTICLES: NONESUPERSEDES: 98-23-24WARRANTY STATUS: INFORMATION ON

Inoperative
Ignition Switch Lock Cylinder: Service and RepairCylinder Inoperative

NOTE:
The following procedure applies to vehicles in which the ignition switch lock cylinder is inoperative and the ignition s
REMOVAL
1. Disconnect battery ground cable.2. Remove steering wheel.3. Through the access hole in the lower shroud, use a s
drill.
44 mm (1-3/4 inch)4. Using channel lock pliers or vise grip pliers, twist lock cylinder cap until it separates from the
lock cylinder breaks loose from breakaway base of lock cylinder. Remove lock cylinder and drill shavings from l
6. Remove retainer, washer, ignition switch lock cylinder and actuator. Thoroughly clean all drill shavings and other
INSTALLATION
1. Replace lock cylinder housing if damaged.2. Install the steering column lock gear and steering column lock housin
3. Install the trim and electrical parts.4. Install ignition switch lock cylinder.5. Install steering wheel.6. Connect batte
Inoperative > Page 1029
Ignition Switch Lock Cylinder: Service and RepairCylinder Operative
The following procedure applies to vehicle that have a functional ignition switch lock cylinder. Lock cylinder keys are
REMOVAL
1. Disconnect the battery ground cable.2. Turn the ignition switch lock cylinder to the RUN position.3. Place a 3.17 m
cylinder. Depress the retaining pin while pulling out on the ignition switch lock cylinder to remove it from the ste
INSTALLATION
1. Install the ignition switch lock cylinder by turning it to the RUN position and depressing the retaining pin. Insert th
into the steering column lock cylinder housing. Make sure the ignition switch lock cylinder is fully seated and ali
2. Rotate the ignition switch lock cylinder using lock cylinder key to make sure the switch works in all positions.3. C
> Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls for Air Bag Deactivati
Recall - Airbag Deactivation Switch Durability Concern
98S20Technical Service Bulletin #
SAFETY RECALL98920
Ford After-Market Airbag On/Oft Switches
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIII^
Attachment Information - Call 1-800-325-5621
^ Customer Notification Letter

> Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls for Air
Bag Deactivation Switch: > 98S20 > Aug > 98 > Recall - Airbag Deactivation Switch Durability Concern > Page 1039


OASISOASIS will be activated for VIN's of vehicles having the affected on/off switches installed for which Ford has t
CLAIMS SUBMISSIONEnter claims using DWE. See ACESII Manual, Sections 5 and 6.
WARRANTY AND POLICY MANUALObserve "Time Recording" policy in the Warranty and Policy Manual Section
SPECIAL CLAIMING INSTRUCTIONS FOR VEHICLES NOT ON OASISIf you provide this recall service for an el
LABOR ALLOWANCES

PARTS REQUIREMENTSParts will not be direct shipped for this recall. Order your parts requirements through norma
DEALER PRICEFor latest prices, check or call your:
^ Order Processing Center
^ DOES II
^ Updated Price Book
STOCK PURGE REQUESTRefer to DOES II bulletin 2555 purge of airbag on/off switch part numbers (F8DZ-14B38

TECHNICAL INSTRUCTIONS
The technical instructions are being provided under separate cover to dealers that received the "A" level suffix parts (F8


> Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletin
98S20 > Aug > 98 > Recall - Airbag Deactivation Switch Durability Concern
SAFETY RECALL98920
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIII^

> Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Air Bag Deactivation Switch: > 98S20 > Aug > 98 > Recall - Airbag Deactivation Switch Durability Concern > Page 1049


LABOR ALLOWANCES

^ DOES II



> Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications
Impact Sensor: Specifications

10.2-13.8 (90-122)Front Air Bag Sensor and Bracket .........................................................................................................

> Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 1057
Impact Sensor: Locations

Engine View
The Front Crash Sensor is located at the LH Front of the vehicle, on front of upper radiator support.
> Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 1058
Impact Sensor: Service and Repair

REMOVAL
one minute1. Record pre-set radio frequencies for reprogramming following completion of service procedures.2. Di
3. Remove radiator upper sight shield.4. Disconnect front air bag sensor and bracket electrical connector.
5. Remove three screws retaining front air bag sensor and bracket at the LH front of radiator support and remove fron
INSTALLATION
1. Position front air bag sensor and bracket in vehicle and secure front air bag sensor and bracket to LH front of radia
12 N.m (9 Lb-Ft).sensor-to-radiator support screws. Tighten screws to
2. Connect front air bag sensor and bracket wire lead connector to wiring assembly connector and secure wiring retai
> Sensors and Switches > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Locations
Safing Sensor: Locations

The Safing Sensor is an intergal part of the Air Bag Electronic Crash Sensor, which is located behind RH side of the in
> Sensors and Switches > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Locations > Page 1062
Safing Sensor: Description and Operation

The Safing Sensor is contained within the Air Bag Electronic Crash Sensor Module.
> Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks
Article No.99-24-2
11/29/99

> 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 1069


NOTE

^
^
NOTE

NOTE

NOTE
NOTE

> Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Cylinder Inope

NOTE:
REMOVAL
drill.
INSTALLATION
> Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Cylinder Inope
REMOVAL
INSTALLATION
> Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations
Neutral Safety Switch: Locations
Transmission View

> Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 1080
> Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Specifications
Steering Angle Sensor: Specifications

TIGHTENING SPECIFICATION
Shock Absorber Electronic
Steering Sensor Screws ..............................................................................................................................................
> Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Specifications > Page 108
Steering Angle Sensor: Locations

The Steering Wheel Rotation Sensor is located at the bottom of the steering column.
> Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Specifications > Page 108
Steering Angle Sensor: Description and Operation
An 30 rpmshock
optical (15 rpmabsorber electronic steering wheel rotation sensor (photocell), mounted on the lower steering colum
When the steering wheel rotation rate reaches for air suspension model), the output current to the power steering
- 60 rpm
Once the steering wheel rotation rate reaches or greater, the output current to the power steering control valve ac
- 30 rpm,
After the steering wheel rotation rate drops below the output current returns to the amount of current regulated b
> Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Sens
Steering Angle Sensor: Service and RepairSensor
REMOVAL
1. Disconnect shock absorber electronic steering sensor electrical connector from wiring harness.2. Remove sensor e
INSTALLATION
2-3 Nm (18-26 inch lbs.).1. Follow removal procedure in reverse order.2. Tighten retaining screws to
> Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Sens
Steering Angle Sensor: Service and RepairSensor Ring
REMOVAL
1. Remove steering column.2. Remove steering shaft from steering column to remove sensor ring.
INSTALLATION
Follow removal procedure in reverse order.
> Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Spec
Ride Height Sensor: Specifications

Mounting Bracket To Lateral Arm ......................................................................................................................................
Ride Height Sensor: Locations

The Linear Height Sensor is located below LH rear of vehicle, attached to the rear upper control arm.
Ride Height Sensor: Description and Operation
DESCRIPTION
TheVehicle is at trim
air suspension height.
height sensor sends signals to the control module through Circuits 427 (PK/BK) and 428 (O/BK).
- Vehicle is below trim height.
- Vehicle is above trim height.
OPERATION
TheIsairconnected to the
suspension frame
height crossmember
sensor is installedatand
oneoperates
end andas
at follows:-
the LH rear suspension arm and bushing at the other end
- The air suspension height sensor gets shorter when the rear of the vehicle lowers and longer when the rear of the
- Magnets mounted in the lower slide portion of the air suspension height sensor move relative to the air suspensio
-
This movement generates a signal that is sent to the control module through two small Hall effect switches attach
- he signal generated by movement of the magnets determines switch opening and closing as follows:
- At trim height, the switches remain closed and the control module receives a trim signal.
- Upward movement of the magnets will open one switch to indicate a high condition.
- Downward movement of the magnets will open the other switch to indicate a low condition.
Ride Height Sensor: Service and Repair
REMOVAL
1. Hoist vehicle. Suspension must be at full rebound.
2. Disconnect electrical connector.
NOTE: Before removing air suspension height sensor from ball studs, observe depth of studs in air suspension h
3. Disconnect bottom and then top end of air suspension height sensor from ball studs by depressing spring clip and p
sensor away from ball stud.
INSTALLATION
1. Connect top and then bottom end of air suspension height sensor to ball studs. Make sure ball studs are fully seate
ball stud retainer housings.
2. Connect air suspension height sensor electrical connector.3. Lower vehicle.4. Turn air suspension switch ON.
> Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Specifications

> Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Specifications > Page 1

> Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Specifications > Page 1
An 30 rpmshock
- 60 rpm
- 30 rpm,
> Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > S
REMOVAL
INSTALLATION
> Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > S
REMOVAL
INSTALLATION
> Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Locations
Suspension Mode Switch: Locations
The air suspension switch, located on the LH side of the luggage compartment, must be turned OFF when the vehicle is
> Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Locations > Page 11
Suspension Mode Switch: Description and Operation
NOTE:
The air suspension switch must be turned to the OFF position when the vehicle is hoisted, jacked, towed, jump started
The air suspension service switch provides the system enable signal to the vehicle dynamics control module in the ON
> Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Locations > Page 11
Suspension Mode Switch: Service and Repair

REMOVAL
1. Disconnect electrical connector.2. Depress retaining clips retaining switch to brace and remove air suspension serv
INSTALLATION
1. Push switch into position in brace, making sure retaining clips are fully seated.2. Connect electrical connector.
> Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Vehicle Speed Sensor Signal > Component Information > Specifications
Vehicle Speed Sensor Signal: Specifications

Retaining Bolt ......................................................................................................................................................................
> Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Vehicle Speed Sensor Signal > Component Information > Specifications >
Vehicle Speed Sensor Signal: Description and Operation
(VSS) (EVO)
TheThe output
vehicle current
speed to the
sensor power steering
is located control valve
in the transmission actuator
and used toisestablish
a function of vehicle
vehicle speedspeed and
for the the steering
electronic whe
variable
- 16 km/h (10 mph), 100 mAWhen vehicle speed is less than the output current is less than and full power steerin
- 600 mA. 600 mA
144 km/h (90 mph).As vehicle speed increases, the current increases to approximately The current then remains
> Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Vehicle Speed Sensor Signal > Component Information > Specifications >
Vehicle Speed Sensor Signal: Service and Repair
REMOVAL
(VSS)
1. Raise vehicle on a hoist. Remove bolt retaining vehicle speed sensor mounting clip to transmission.2. Remove veh
INSTALLATION
7-10 Nm (62-88 inch lbs.). 1. Position driven gear to vehicle speed sensor. Install gear retainer.2. Connect electrical
> Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Control Switch <--> [Overdrive Switch, A/T] > Component Info
Transmission Control Switch: Description and Operation

(PCM)
(TCIL)
The transmission control switch is a momentary contact switch. When the switch is pressed, a signal is sent to the Powe
OPERATION
TheThe system
column automatically
range engages
selector includes into the OVERDRIVE
transmission mode
control switch each
in the time
shift theknob.-
lever ignition switch is turned to RUN.
-
Pressing the transmission control switch with the ignition switch in RUN locks out the OVERDRIVE mode; pres
> Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletin
Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative
Article No.02-13-6
07/08/02
ISSUE
ACTION
Parts Block

BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
> Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical
Service Bulletins > Customer Interest for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 1129

3.
> Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletin
Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative
Article No.02-13-6
07/08/02
ISSUE
ACTION
Parts Block

BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
> Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 1135

3.
> Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams
Transmission Control Switch

> Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range (TR) Sensor <--> [Transmission Position Switch/
Information > Locations
Transmission View


7 - 10 Nm (62 - 88 inch lbs.).
19 - 26 Nm (14 - 19 ft. lbs.)
REMOVAL
INSTALLATION
(TR)
7 - 10 Nm (62-88 inch lbs.)
19 - 26 Nm (14 - 19 ft. lbs.)
> Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications
Transmission Speed Sensor: Specifications

> Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications >
Transmission Speed Sensor: Locations
Transmission View
The Output Shaft Speed Sensor is located at the LH rear of the transmission.
Transmission Speed Sensor: Diagrams
Output Shaft Speed Sensor

Transmission Speed Sensor: Service and Repair
REMOVAL
(VSS)
1. Raise vehicle on a hoist. Remove bolt retaining vehicle speed sensor mounting clip to transmission.2. Remove Ve
INSTALLATION
7 - 10 Nm (62 - 88 inch lbs.)

1. Position driven gear to vehicle speed sensor. Install gear retainer.2. Connect electrical connector.3. Make sure that
> Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams
Rear Window Defrost Control

> Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams > Page 1156
Heated Glass Element Switch: Description and Operation

- A heated back window switch and light is mounted on the instrument panel.
-
10 minutes
10 minutesThe heated back window switch and light has a push button spring-loaded to neutral position to turn t
- Pushing in the heated back window switch and light electrically closes the normally open contacts in the heated b
- (LCM)
The contacts switch a Lighting Control Module input to ground. The LCM then switches one side of the heated b
- (40 A)Power is supplied from the power distribution box maxi Fuse 14 .
> Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams > Page 1157
Heated Glass Element Switch: Service and Repair
REMOVAL
1. Remove center instrument panel finish panel.2. Remove heated back window switch and light by pressing metal m
INSTALLATION
> Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Window Switch
Left Rear & Right Rear Window Control Switch

> Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Window Switch > Page 1162
> Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Window Switch > Page 1163
> Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > One_Touch Down
Power Window Switch: Description and OperationOne_Touch Down

The LH front window regulator control switch :
- has the one-touch feature.
- activates window regulator electric drive.
- allows the front door window glass to move downward to full down stop when pressed momentarily.
- will stop the front door window glass when momentarily pressed.
- one-half secondwill operate the front door window glass in the standard mode when pressed for more than .
> Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > One_Touch Down > Page 1166
Power Window Switch: Description and OperationWindow Regulator Control Switch

The window regulator control switches are located in door arm rests.
- A master window regulator control switch on the LH front door armrest can be used to activate any or all of the p
- Passenger window regulator control switch activates the power window for individual doors only.
> Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Doors
Power Window Switch: Service and RepairFront Doors

REMOVAL
1. Disconnect battery ground cable.2. Remove screw and pry up gently on the window regulator switch housing start
control switch at passenger door.
5. Carefully pry the window regulator control switch from the connector with a small screwdriver. Take care not to d
pins.
INSTALLATION
> Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Doors > Page 1169
Power Window Switch: Service and RepairRear Door Window Regulator Control Switch
REMOVAL
1. Gently pry up the front portion of the window regulator switch housing.2. Remove the two screws retaining the co
pins.
INSTALLATION
> Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation
Washer Fluid Level Switch: Description and Operation
NOTE: Windshield washer reservoir fluid level sensor cannot be replaced separately. If switch needs to be replaced, th
- The windshield washer reservoir fluid level sensor is mounted in the windshield washer reservoir.
- It consists of a float and a magnet assembly that opens and closes a reed-type switch.
-
When the windshield washer pump is energized, current will flow from the windshield washer reservoir fluid lev
> Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations
> Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions
Windshield Washer Switch: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions >
Windshield Washer Switch: Connector Views
> Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions >
Multi_function Switch - Schematic - Wiper/Washer Portion Of Multi-function Switch

> Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 1188
Windshield Washer Switch: Description and Operation

Theturn signal.
- hazard warning.
- cornering lamps.
- headlamp dimmer.
OPERATION
TheThe ignition washer

windshield switch lock cylinder
switch, must
located be end
at the in RUN position
of the to operate
turn signal lever, washer.
operates as follows:-
- Push the end of the turn signal lever in toward the center of the steering actuator housing to actuate the washe
- Release the turn signal lever to turn off the washer.
- The windshield wipers will continue to operate briefly and then automatically return to the previous wiper spe
- Washer operation is available in all positions of wiper operation.
> 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

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).
See: Pinpoint Tests/A: No Communication With Lighting Control Module
> Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1
Windshield Washer Switch: Initial Inspection and Diagnostic Overview

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).
Windshield Washer Switch: Symptom Related Diagnostic Procedures

Windshield Washer Switch: Pinpoint Tests

> Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of
Diagnosis > Page 1194

Pinpoint Test G1

Windshield Washer Switch: Component Tests and General Diagnostics



> Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 1199
Windshield Washer Switch: Service and Repair
REMOVAL
INSTALLATION
> Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations
> Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions
Wiper Switch: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Page 1205

> Page 1206

System Diagrams
> Page 1207

Grounds Diagrams
> Page 1208

ELECTRICAL SYMBOLS
Electrical Symbols
> Page 1209

Electrical Symbols
VACUUM SYMBOLS
> Page 1210

Vacuum Symbols

BK
BL
BR
> Page 1211

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1212
Wiper Switch: Connector Views
> Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1213

> Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 1214
Wiper Switch: Description and Operation

Theturn signal.
- hazard warning.
- cornering lamps.
- headlamp dimmer.
OPERATION
- windshield washer/wiper The intermittent wiper control switch, located in the knob at the end of the turn signal le
- The ignition switch lock cylinder must be in RUN position to operate wiper.
- In addition to O (OFF position), there are two fixed wiper speed positions, LO and Hi, as well as an interval posit
- Positions are selected by rotating knob actuator relative to the turn signal lever.
-
If the interval position is selected, the time between wiper cycles will decrease as the knob is rotated away from t
- The time interval between wipes will vary depending on knob's position from OFF.
> 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

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).
See: Windows and Glass/Testing and Inspection/Diagnostic Trouble Code Descriptions/LCM Diagnostic Trouble Cod
> Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1217
Wiper Switch: Initial Inspection and Diagnostic Overview

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).
Wiper Switch: Symptom Related Diagnostic Procedures

Wiper Switch: Pinpoint Tests

> Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page
1220

1221

1222

Pinpoint Test G1
1223

Wiper Switch: Component Tests and General Diagnostics

1225

1226

> Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 1227
Wiper Switch: Service and Repair
REMOVAL
INSTALLATION
> Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure
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, THUNDERBIRD1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG,
LINCOLN-MERCURY:1995-1997 COUGAR1995-1998 MARK VIII1995-1999 CONTINENTAL, GRAND MARQU
LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-3501995-1999 ECONOLINE, EXPLORER, F-150, F-250
ISSUEThis TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic proce
ACTIONUtilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUS
Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4970
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 Pr
DIAGNOSIS AND TESTING
Noise, Vibration and Harshness (NVH)
> Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1233

Component Tests Diagnostic Process
1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road
NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts
GENERAL PROCEDURES
Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check
Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be
Acceptable Noise, Vibration and Harshness
All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environmen
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
^ Choose the appropriate flowchart.
^ Identify the operating condition that the vehicle is exhibiting.

^ 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-LightAn increase in speed at less than half throttle.
Acceleration-MediumAn increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximatel
Acceleration-HeavyAn increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20
Ambient TemperatureThe surrounding or prevailing temperature.
AmplitudeThe quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a
BacklashGear teeth clearance.
BoomLow frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming.
Bound UpAn overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it.
Brakes AppliedWhen the service brakes are applied with enough force to hold the vehicle against movement with the tr
Buffet/BuffetingStrong noise fluctuations caused by gusting winds. An example would be wind gusts against the side g
BuzzA low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high f
CamberThe angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Cambe
CasterThe angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle.
ChatterA pronounced series of rapidly repeating rattling or clicking sounds.
ChirpA short-duration high-pitched noise associated with a slipping drive belt.
ChuckleA repetitious low-pitched sound. A loud chuckle is usually described as a knock.
ClickA sharp, brief, non-resonant sound, similar to actuating a ball point pen.

ClonkA hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering.
Clunk/Driveline ClunkA heavy or dull, short-duration, low-frequency sound.Occurs mostly on a vehicle that is accelera
Coast/DecelerationReleasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without apply
Coast/Neutral CoastPlacing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at c
Constant Velocity (CV) JointA joint used to absorb vibrations caused by driving power being transmitted at an angle.
Controlled Rear Suspension HeightThe height at which a designated vehicle element must be when driveline angle mea
Coupling ShaftThe shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front s
CPSCycles per second. Same as hertz (Hz).
CracksA mid-frequency sound, related to squeak. Sound varies with temperature conditions.
CreakA metallic squeak.
CruiseConstant speed on level ground; neither accelerating nor decelerating.
CycleThe process of a vibrating component going through a complete range of motion and returning to the starting poin
DecibelA unit of measurement, referring to sound pressure level, abbreviated dB.
Drive Engine Run-Up (DERU) TestThe operation of the engine through the normal rpm range with the vehicle standin
Driveline AnglesThe differences of alignment between the transmission output shaft, the drive shaft, and the rear axle p
DriveshaftThe shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the re
DrivetrainAll power transmitting components from the engine to the wheels; includes the clutch or torque converter, th
Drivetrain DamperA weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight
DroneA low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan.
DrummingA cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the
Dynamic Balance

The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is
Engine ImbalanceA condition in which an engine's center mass is not concentric to the rotation center. Excessive motio
Engine MisfireWhen combustion in one or more cylinders does not occur or occurs at the wrong time.
Engine ShakeAn exaggerated engine movement or vibration that directly increases in frequency as the engine speed inc
Flexible CouplingA flexible joint.
FloatA drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed wi
FlutterMid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind.
FrequencyThe rate at which a cycle occurs within a given time.
Gravelly FeelA grinding or growl in a component, similar to the feel experienced when driving on gravel.
GrindAn abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood.
HissSteady high frequency (200-800 Hz) noise. Vacuum leak sound.
HowlA mid-range frequency noise between drumming and whine.
HumMid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl.
HzHertz; a frequency measured in cycles per second.
ImbalanceOut of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration
InboardToward the centerline of the vehicle.

IntensityThe physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher th
HootA steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle.
IsolateTo separate the influence of one component to another.
KnockA heavy, loud, repetitious sound, like a knock on the door.
MoanA constant, low-frequency (100-200 Hz) tone. Also described as a hum.
Neutral Engine Run-Up (NERU) Test


The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengag
Neutralize/NormalizeTo return to an unstressed position. Used to describe mounts. Refer to Bound Up.
NVHNoise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying d
OutboardAway from the centerline of the vehicle.
PingA short duration, high-frequency sound, which has a slight echo.
Pinion ShaftThe input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring a
PitchThe physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa.
Pumping FeelA slow, pulsing movement.
Radial/LateralRadial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation.
RattleA random and momentary or short duration noise.
Ring GearThe large, circular, driven gear in a ring and pinion gearset.
Road TestThe operation of the vehicle under conditions intended to produce the concern under investigation.
RoughnessA medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibratio
RunoutOut of round and wobble.
RustlingIntermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves.
ShakeA low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels
ShimmyAn abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation

ShudderA low-frequency vibration that is felt through the steering wheel or seat during light brake application.
SlapA resonance from flat surfaces, such as safety belt webbing or door trim panels.
Slip Yoke/Slip SplineThe driveshaft coupling that allows length changes to occur while the suspension articulates and w
SqueakA high-pitched transient sound, similar to rubbing fingers against a clean window.
SquealA long-duration, high-pitched noise.
Static BalanceThe equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can c
TapA light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge.
ThumpA dull beat caused by two items striking together.
TickA rhythmic tap, similar to a clock noise.
Tip-In MoanA light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph).
TIRTotal indicated run out
Tire DeflectionThe change in tire diameter in the area where the tire contacts the ground.
Tire Flat SpotsA condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be

Tire Force VibrationA tire vibration caused by variations in the construction of the tire that is noticeable when the tire r
TransientMomentary, short duration.
Two-Plane BalanceRadial and lateral balance.
VibrationAny motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and dow
WhineA constant, high-pitched noise. Also described as a screech.
WhistleHigh-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turboc
Wind NoiseAny noise caused by air movement in, out or around the vehicle.
WOTWide-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. T

The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH pro
a.
Test drive the vehicle with the vibration sensorinside the vehicle.
b. Place the sensor in the vehicle according to feel.
If the condition is felt through the steeringwheel, the source is most likely in the front ofthe vehicle.
A vibration that is felt in the seat or floor onlywill most likely be found in the driveline,drive axle or rear whe
c.
Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to d
- 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 H
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.

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.
Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibrati
Vibrate Software(R)
Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of

engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular vel
^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and e
^ 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
- 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 bein
EngineEAR
An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged
Ultrasonic Leak Detector
The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-str
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
^ PVC (soft foam) tape
^ Urethane (hard foam) tape
^ Flocked (black fuzzy) tape
^ UHMW (frosted) tape
^ Squeak and rattle oil tube

^ 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. The
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 impr
Dollar bill or 3x5 Card

Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw th
Diagnosis and Testing
Special Service Tool(s)
Diagnostic Process



To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with th
To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each
1. Customer Interview
The diagnostic process starts with the customer interview. The service advisor must obtain as much information as poss

^ 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
important
It is to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe
The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will co
3. Preparing For the Road Test
Observe the following when preparing for the road test:
^ importantReview the information recorded on the NVH Diagnostic Guide. It is to know the specific concern the c
^ 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 vibratio
^
Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an o
^
If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make n
^
The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer
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 m
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 te
The following is a brief overview of each test in the order in which it appears. A review of this information helps to qui
^
The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially whe
^ 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
^ 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 determi

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
^ 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
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 po
^ 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
^ 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.
Neutral Coast Down Speed Test
^ 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 tor
^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the co
Downshift Speed Test

^ 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, brak
^ If necessary, repeat this test using other gears and NEUTRAL to verify the results.

Steering Input Test
^ 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 applicati
Brake Test
^
Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications
^ 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
Road Test Over Bumps
^
Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the fro
Neutral Engine Run-up (NERU) Test
^ In stall a tachometer.
^
Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles w
^ Attempt to identify what part of the vehicle the concern is coming from.
Drive Engine Run-up (DERU) Load Test

^ WARNING:
Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can re
^ CAUTION:
Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can
Block the front and rear wheels.
^ Apply the parking brake and the service brake.
^ Install a tachometer.

^
Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 200
^ Repeat the test in REVERSE.
^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mou
^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source.
Engine Accessory Test
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
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 loc
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: gea
^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known)
^ 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 suspens
^ 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 o
^ 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 concern
If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious
7. Diagnostic Procedure
Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom

^ 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 c
- If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be ca
^ 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 Noi
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 - IdleNoise/Vibration.
^
Idle vibration or shake. GO to SymptomChart - Idle Noise/Vibration.
4. During Gear Selection
1.
Vehicle parked on a steep incline. Acceptablenoise.
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 No
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. GOto Symptom Chart - TireNoise/Vibration.
-
Noise occurs at specific vehicle speed.A high-pitch noise (whine). GO toSymptom Chart - Driveline
-
Loudness proportional to vehiclespeed. Low-frequency noise at highspeeds, noise and loudness incr

-
A low-pitched noise (drumming). GOto Symptom Chart - EngineNoise/Vibration.

-
Tire Noise/Vibration.
Vibration occurs at a particular speed(mph) regardless of acceleration ordeceleration. GO to Sympto
-
Airvaries
Noise Leak with
and Wind Noise. speedand direction. GO to Symptom Chart-
wind/vehicle
^ 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 -
^ 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 SymptomChart - 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 toSymptom Chart - BrakeNoise/Vibration.
^
Brake vibration/shudder. GO to SymptomChart - Brake Noise/Vibration.
5. Clutching
A noise occurring during clutch operation.GO to Symptom Chart - Transmission(Manual) and Transfer
^ Vibration. GO to Symptom Chart -

Transmission (Manual) and TransferCase Noise/Vibration.
6. Shifting
^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart - Transmiss
^
Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual)
7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vib
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 - SuspensionNoise/Vibration.

^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and
^ 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



































Pinpoint Tests
The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not alwa































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 6.3
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 p

Rotate the steering wheel to the RH stop. then turn the steering wheel 90 back from that position. Turn the steerin
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 prod
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 work
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 "
6.
Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring ge
7.
A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should alway
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.

^
The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the
9. A high, thin contact pattern that is worn toward the toe.
^ 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.
^ 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.

^ 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, coast
Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or w
For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm
^ Measure the diameter of the tire.
^
Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from th
If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). M


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 suspen
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).
6. Tighten the powertrain/drivetrain mount fasteners.
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 le
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 a
1. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air s

CAUTION:
Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause o
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 catalyti
^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applie
^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward.
8. Test the exhaust system for normal operation.

Wheel Bearing Check
1. WARNING:
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
Spin the tire by hand to check the wheel bearings for roughness.

3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the
4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry
^
On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install
^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for t
> Maintenance > Alignment > System Information > Specifications > Alignment
Alignment: SpecificationsAlignment
NOTE: All specifications are given for a vehicle at curb height with 1/2 tank of fuel.
CAMBER:
Nominal ............................................................................................................................................................................
Nominal ......................................................................................................................................................................
CASTER:
Nominal ............................................................................................................................................................................
Nominal ......................................................................................................................................................................
TOTAL TOE [a]

Degree:
Nominal ......................................................................................................................................................................
mm/inch:
Nominal ......................................................................................................................................................................
CLEAR VISION [b]:
Nominal ............................................................................................................................................................................
TURNING ANGLE [c] ......................................................................................................................................................
[a]
[b]
20.Turning
[c]Positive valueangle at outside
is toe-in, wheel
negative with
value inside wheel turned
is toe-out.Position of steering wheel spoke to horizontal. Negative value spec
> Maintenance > Alignment > System Information > Specifications > Alignment > Page 1330
Alignment: SpecificationsSuspension Height
1. Examine the vehicle for indications of abnormal attitude, such as the front or rear end being higher or lower than n
SUSPENSION HEIGHT
Front(#1) .....................................................................................................................................................................
SUSPENSION HEIGHT (w/ Air Suspension)
Front(#1) .....................................................................................................................................................................
SUSPENSION HEIGHT (w/ Handling Package)
Front(#1) .....................................................................................................................................................................
SUSPENSION HEIGHT (Police or CNG)
Front(#1) .....................................................................................................................................................................
Note #1: For front measurement, record measurement A (lowest point on suspension arm) and B (center of housing bo
> Maintenance > Alignment > System Information > Specifications > Page 1331
> Maintenance > Alignment > System Information > Specifications > Page 1332
> Maintenance > Alignment > System Information > Service Precautions > Technician Safety Information
Alignment: Technician Safety Information
WARNING: DO NOT REMOVE AN AIR SPRING UNDER ANY CIRCUMSTANCES WHEN THERE IS PR
> Maintenance > Alignment > System Information > Service Precautions > Technician Safety Information > Page 1335
Alignment: Vehicle Damage Warnings
WARNING: THE ELECTRICAL POWER SUPPLY TO THE AIR RIDE CONTROL SYSTEM MUST BE SH
NOTE:
Incorrect hoisting
Hoisting/Lifting - can damage steering linkage components and front suspension components.
-
Before hoisting/lifting turn the air suspension switch (if equipped) OFF. It is located in LH side of luggage co
> Maintenance > Alignment > System Information > Service and Repair > Caster and Camber
Alignment: Service and RepairCaster and Camber
DESCRIPTION
Camber is the amount the centerline of the wheel is tilted inward or outward from the true vertical. If a wheel tilts
The caster is the forward or rearward tilt of the top of the front wheel spindle. If the top of the front wheel spindle
PROCEDURE
NOTE: Adjusting cams are provided for caster and camber adjustment.
1. Check caster and camber and record the readings.
> Maintenance > Alignment > System Information > Service and Repair > Caster and Camber > Page 1338

2. Compare camber and caster readings with nominal specifications on appropriate chart (depending on vehicle) to d
-3/4 degree
required to bringtovehicle
+3/4 degree Maximum
to nominal camber difference between wheels (left minus right) to be within with
setting.-
- -3/4 degree to +3/4 degreeMaximum caster difference between wheels (left minus right) to be within with ca
NOTE:
A vehicle within the minimum to maximum tolerances may require alignment adjustment to the nominal setting
148-201 Nm (109-143 ft. lbs.). 3. If adjustment is required, loosen two nuts on top of adjusting cams.4. Turn hex cam
Alignment: Service and RepairComponent Inspections

NOTE: When trying to correct for pull/drift refer to the following conditions.
Vehicle will pull/drift:

- toward the side with the most positive camber.
- toward the side with the least positive caster.
- toward the low side if vehicle is leaning.
NOTE: Side-to-side ride height variation can cause side-to-side camber variation.
Alignment: Service and RepairCurb Load
Check the front-wheel alignment under the following curb load conditions:1. Oil level and radiator filled to specifica
Alignment: Service and RepairPreliminary Inspection

DESCRIPTION
-
Adjusting the camber affects caster and toe. Adjusting the caster affects toe. The recommended adjustment seque
- For descriptions of alignment terms and specifications see the reference definitions. See: Diagrams
PROCEDURE
- Do not attempt to check and adjust front-wheel alignment without first making a preliminary inspection of the fro
-
Check all the factors affecting front-wheel alignment adjustments except the turning angle before making any adj
- Begin by checking curb load condition. See: Curb Load
-
Before checking or adjusting front wheel alignment settings, the Accurate Trim Test must be performed. See: Ste
- After all the front-wheel alignment factors have been checked, make the necessary adjustments.
NOTE: Do not attempt to adjust front-wheel alignment by bending the suspension or steering parts.
Alignment: Service and Repair
Caster and Camber
DESCRIPTION
PROCEDURE

-3/4 degree
required to bringtovehicle
+3/4 degree Maximum
to nominal camber difference between wheels (left minus right) to be within with
setting.-
NOTE:
Component Inspections

Curb Load
Preliminary Inspection
DESCRIPTION
-
PROCEDURE
-
-
Before checking or adjusting front wheel alignment settings, the Accurate Trim Test must be performed. See: Ste
Steering Angle

NOTE: Perform the steering angle check before toe-in measurement (if any steering angle corrections have been made
DESCRIPTION
Steering
Check gear.steering angles at full right and left positions. If the angles are not within specification, the tie ro
the wheel
- Steering column.
- Intermediate shaft universal joints.
- Steering wheel.
Toe & Steering Wheel Centering (Clear Vision)

DESCRIPTION
After adjusting caster and camber, check the steering wheel spoke position with the front wheels in straight-ahead po
NOTE: Toe should only be checked and adjusted after the caster and camber have been adjusted to specification.
PROCEDURE
Check the toe with the front wheels in the straight-ahead position. Run the engine so the power steering control valve

1. Loosen the two clamp bolts on each front wheel spindle tie rod adjusting sleeve.
2. Adjust toe. If the steering wheel spokes are in their normal position, lengthen or shorten both rods equally to obtai
wheel spokes are not in their normal position make the necessary rod adjustments to obtain correct toe and steerin

Sleeve Position
3. When toe and the steering wheel spoke position are both correct, lubricate clamp, bolts and nuts. Tighten the clam
27-30 Nm (20-22 ft. lbs.).
spindle tie rod adjusting sleeves to The sleeve position should not be changed when the clamp bolts are tightened
Wheel Turning Angle

NOTE:
If the turning angle does not measure to specification, check the front suspension lower arm and other suspension or s
20,
If the
18.51. Theturning
turningangle
angledoes not measure
cannot to specification,
be adjusted check
directly because it isthe suspension,
a result frame
of caster, or steering
camber and toeparts for a bent
adjustments con
comb
> Maintenance > Alignment > System Information > Service and Repair > Page 1347
Alignment: Tools and Equipment

-
1.59 mm (1/16-inch)
Equipment used for alignment inspection must be accurate. All wheel alignment readings must be performed on a
-
Install the wheel alignment equipment on the vehicle and follow the installation and inspection instructions provi
> Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications
Fuel Pressure Test Port: Specifications
Fuel Pressure Relief Valve to Supply Manifold ..................................................................................................................

> Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 1353
Fuel Pressure Test Port: Description and Operation

The fuel pressure relief valve:
- is used to relieve fuel pressure from the fuel delivery system.
- is located on the fuel injection supply manifold.
> Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 1354
Fuel Pressure Test Port: Service and Repair

REMOVAL
1. Perform Pre-Service procedures and Fuel Pressure Release.2. Using an open-end wrench or suitable deep-well soc
NOTE: Cap on fuel pressure relief valve must be removed.
INSTALLATION
7.75 Nm (68 lb in)
0.6 Nm (5 lb in)1. Install fuel pressure relief valve. Tighten fuel pressure relief valve to .2. Perform Fuel Charging S
> Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications
Idle Speed: Specifications

Hot Idle ................................................................................................................................................................................
> Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1358
Idle Speed: Adjustments

The throttle body for this vehicle cannot be adjusted.
> Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation
Air Filter Element: Description and Operation

ACLThe Air Cleaner element ( element) is a:
- dry-type air cleaner element.
-
chemically treated, pleated paper air filtering element which permits air flow through the air induction system, fil
> Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation > Page 1363
Air Filter Element: Testing and Inspection

CAUTION: ACL Cleaning the Air Cleaner element ( element) is not recommended. Cleaning the air cleaner element
The air cleaner element should be replaced at the specified mileage intervals.
Visually inspect the air cleaner element for signs of dust or dirt leaking through holes in the filter media or past the seal
Also check the air cleaner element for deformed seals or brittle spots that could fail under engine operation and cause a
> Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation > Page 1364
Air Filter Element: Service and Repair
ACLRefer to the Maintenance Schedule for the emissions scheduled maintenance for frequency of inspection and/or re
REMOVAL
1. Unfasten two retaining clips on engine air cleaner to remove the air cleaner cover.2. Remove air cleaner element f
INSTALLATION
1. Clean all inside surfaces of the engine air cleaner.2. Install the air cleaner element.3. Position air cleaner cover on
> Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions
Fuel Pressure Release: Service Precautions
WARNING: Do not smoke, carry lighted tobacco or an open flame of any type when fueling vehicle or when wo
NOTE
: Methanol and ethanol are not interchangeable. Methanol fuel can be used only in vehicles designed for methanol fuels
WARNING: The fuel tubes leading from the fuel tank to the engine are under pressure during vehicle operation
WARNING: Do not swallow fuel of any kind. Fuels such as methanol or fuel ethanol and gasoline or mixtures o
AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR OF ANY KIND CAN LEAD TO EY
WARNING: Do not modify the fuel system configuration or components or replace components with parts not
WARNING: Do not operate engine or smoke while refueling.
WARNING: Use of the incorrect fuel or blending of fuels can result in severe engine damage. Refer to fuel fille
WARNING: It is important that your flexible fuel vehicle be properly maintained by ford flexible fuel trained p
> Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1369
Fuel Pressure Release: Service and Repair
Fuel Pressure Gauge
Special Tool(s)
WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WH
FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NO
1. Remove the Schrader valve cap and install the EFI/CFI Fuel Pressure Gauge.
2. Slowly open the manual valve on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure this will drain som
the fuel in a suitable container.
> Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications
Firing Order: Specifications
Firing Order 1-3-7-2-6-5-4-8
Coil On Plug
> Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations
> Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap
Spark Plug: SpecificationsGap
Spark Plug Gap .................................................................................................................................................................. 1

> Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 1381
Spark Plug: SpecificationsTorque
Spark Plug Gap .................................................................................................................................................................. 1

> Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1382
Spark Plug: Application and ID

Spark Plug Type ...................................................................................................................................................................
Spark Plug: Testing and Inspection

Clean spark plugs as necessary with a wire brush or professional spark plug cleaner (follow manufacturer's instructions
Spark Plug: Adjustments

1.3-1.4 mm (0.052-0.056 inch)Using a suitable spark plug gap tool, adjust spark plug gap to following the tool manufa
Spark Plug: Service and Repair


REMOVAL
1. Remove the coil-on-plug units from spark plug.2. Loosen spark plugs 1/4 turn and remove any dirt or foreign mate
NOTE: Refer to the Spark Plug Inspection Chart to determine the condition of the spark plugs.
INSTALLATION
9-20 Nm (80-177 lb in)1. Follow the removal procedure in reverse order.2. Tighten spark plugs to .
> 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 7
If one or more cylinders reads low, squirt approximately one tablespoon of clean engine oil meeting Ford specific
> Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Compression Test
Compression Check: Testing and InspectionCompression Test
COMPRESSION GAUGE CHECK

1. Make sure oil in crankcase is of the correct viscosity and at proper level, and battery is properly charged. Operate
operating temperature. Turn ignition switch to the OFF position, and remove all spark plugs.
2. Install a compression gauge such as Rotunda Compression Tester 303-F011 or equivalent in No.1 cylinder.3. Insta
compression strokes and record highest reading. Note the approximate number of compression strokes required to
4. Repeat test on each cylinder, cranking the engine approximately the same number of compression strokes.
TEST RESULTS
The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 p
> Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Compression Test > Page 1392
Compression Check: Testing and InspectionInterpreting Compression Readings
If one or more cylinders reads low, squirt approximately one tablespoon of clean engine oil meeting Ford specification
1. If compression improves considerably, piston rings are damaged.2. If compression does not improve, valves are st
leaking between cylinders. Engine oil and/or coolant in cylinders could result.
Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading numb
Example Readings
If, after checking the compression pressures in all cylinders, the highest reading was 1351 kPa (196 psi) and the lowest
> Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications
Valve Clearance: Specifications

The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment.
> Maintenance > Drive Belt > Component Information > Diagrams
Drive Belt: Diagrams
Drive belt installation

Part 1 Of 2
> Maintenance > Drive Belt > Component Information > Diagrams > Page 1399

Drive Belt Routing, Part 2 Of 2
> Maintenance > Drive Belt > Component Information > Diagrams > Page 1400
Drive Belt: Description and Operation

(FEAD)
TheEngines equipped
4.6L (2V) with anare
OHC engines automatic
equippeddrive
withbelt tensionerFront
a multi-vee will not
Endrequire any drive
Accessory Drivebelt tension
belt adjustment
to ensure maximumfor
- Loose drive belts will result in slippage which may cause a noise complaint or improper accessory operation.
- Loose drive belts may result in operational problems like generators not delivering proper charge or other con
Drive -belts with automatic drive belt tensioners do not require adjustment.
NOTE:
-
When an accessory drive belt is replaced or reinstalled after a service procedure, the drive belt does not fully seat
Thisa vehicle
V-ribbedis serpentine accessory drive belt.
equipped with:-
- an automatic drive belt tensioner.
Replacement drive belts should be of the same type as originally installed.
Theatdrive
160,000
belt km (100,000
condition miles),
should be checked:-
- then every 24,140 km (15,000 miles).
> Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Drive Belt: Initial Inspection and Diagnostic Overview
1. Verify the customer's original concern by operating the engine to duplicate the condition.2. Inspect to determine if
Drive belt noise or squeal.

Mechanical-
- Pulley misalignment or excessive pulley runout.
3. Inspect for drive belt cracking/chunking/wear.4. If inspection reveals obvious concern(s) that can be readily identi
Procedures
> Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1403
Drive Belt: Symptom Related Diagnostic Procedures
Part 1 Of 2
Part 2 Of 2
Drive Belt: Component Tests and General Diagnostics
Cracking/Chunking/Wear
Under severe operating conditions (high temperatures, low humidity), drive belt rib cracking can occur at less than 160
- is not a reason for concern.
- has no detrimental effect on drive belt performance. However, cracks running with backing are not acceptable.
The drive belt is still perfectly functional until rib chunking occurs. Drive belt chunking is where the rubber material ac
Drive Belt Chirp
pulley
Drive belt misalignment.
chirp is a regularly occurring chirping noise that occurs due to:-
- excessive pulley runout.
It can be a result of a damaged pulley or an improperly replaced pulley that was not properly aligned.
determine
To correct thebelt
drive areachirp:-
where the noise comes from.
- check each of the pulleys in that area with a straightedge to the crankshaft pulley.
- look for the accessory pulley to be out of position in the fore/aft direction or at an angle to the straightedge.
engine
Drive start-upis an intermittent noise that occurs when the drive belt slips on a pulley during certain condition
belt squeal
- rapid engine acceleration/deceleration
- A/C clutch engagement
Drive belt squeal can occur under the following conditions:-

theA/C
If the A/Cdischarge
system ispressure
overcharged.
goes above 2.895 kPa (420 psi). This can occur if:-
- the A/C condenser
engine airflow
cooling fan is engaging
is not blocked. fully at idle.
-
If any of the accessories are damaged, have a worn or damaged bearing or internal torsional resistance is abov
- If fluids get on the drive belt. This would include power steering fluid, engine coolant, engine oil and air cond
-
If fluid does get on the drive belt during service, clean the drive belt with soap and water and thoroughly rinse
-
If the drive belt is too long. This will allow the arm on the drive belt tensioner to go all the way to drive belt te
NOTE: The drive belt tensioner arm should rotate freely without binding. If the drive belt is worn or damaged, r

-
If the drive belt tensioner is worn or damaged, refer to Component Test. See: Engine, Cooling and Exhaust/E
> Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1406
Drive Belt: Adjustments

The serpentine drive belt has an automatic drive belt tensioner and does not require adjustment.
Drive Belt: Service and Repair
WARNING: DO NOT ALLOW DRIVE BELT TENSIONER TO SNAP BACK AS DAMAGE TO DRIVE BE
NOTE:
Minor cracks in the V grooved portion of the drive belt are considered normal and acceptable. If the drive belt has ch
Conditions requiring drive belt replacement are rib chunk-out, severe glazing, frayed cords or other concerns. Replac
1. Rotate drive belt tensioner away from drive belt with a breaker bar installed in the 0.5 inch square hole in drive be


Part 1 Of 2
3. To install, position drive belt over pulleys. Make sure that all V grooves make proper contact with pulley as shown
NOTE:
- Make sure drive belt is properly installed on each pulley.
- When installing drive belt on pulleys, make sure that all grooves make proper contact with pulleys.
> Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation

-
> Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation > Page 1414

> Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation > Page 1415
REMOVAL
INSTALLATION
> 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
> Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions
NOTE
> Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1423
Fuel Pressure Gauge
Special Tool(s)
> Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications
Oil Filter: Specifications

Filter to Adapter .......................................................................................................................................... 1/2 turn afte
> Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Page 1427
Oil Filter: Service and Repair

REMOVAL
1. Raise vehicle on a hoist. 2. Position a drain pan under oil bypass filter area.3. Unscrew the oil bypass filter from o
5. If removal of the oil filter adapter is required, proceed with the following:
Clean
a. On and inspect
trailer-tow the sealing
and police surfaces
option of the
equipped oil filter
vehicles, adapter gasket
disconnect the oil and cylinder
supply block.hoses from the oil coo
and return
Trailer-Tow And Police Shown, Others Similar
> Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Page 1428

INSTALLATION
1. If only the oil bypass filter was removed, proceed to Step 3. If removal of the oil filter adapter was required, proce
20-30 Nm (15-22 ft. lbs.).
a. Tighten bolts to b. Install the lower radiator hose onto the oil filter adapter. Install the hose clamp securely.c. C
3. Coat rubber seal of oil bypass filter with clean Super Premium SAE 5W30 Motor Oil XO-5W30-QSP.
NOTE:
The oil bypass filter has a 22 mm metric thread and an anti-drain back valve. Make sure the replacement oil bypa
4. Install oil bypass filter on oil filter adapter until rubber seal contacts sealing surface of oil filter adapter.5. Tighten
> Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement
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 VICTORIA1981-98 ESCORT1982-83 FAIRMONT1982-88 EXP1982-97 THUNDERBIRD
LINCOLN-MERCURY:1980-98 GRAND MARQUIS, TOWN CAR1982-83 ZEPHYR1982-86 CAPRI 1982-87 LN71

LIGHT TRUCK:1980-96 BRONCO1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-3501983-98 R
This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years.
ISSUEVehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system c
ACTION
> Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page
1433

Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the followin
SUPERSEDES: 96-15-5
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Mod
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.
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 C

CAUTION
FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APP
1.
Before removing any refrigerant system components, recover the refrigerant from the system following the recyc
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
CAUTION
REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS A
4.
Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the
1434

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 ho
6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated cont
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 T
8.
A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compress
CAUTION
REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-13
^
If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amou
^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrig
9.
Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tig
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 in
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.
1435

13.
Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at
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.
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 RefrigerantSyste
NOTE
THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCL
> Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis
Heater Hose: Customer InterestA/C - Heater Core Electrolysis/Leakage

TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD:1997-2002 Contour1997-2007 Crown Victoria, Mustang, Taurus2000-2007 Focus2002-2005 Thunderbird2005-
2000-2005 Excursion2001-2003 Explorer Sport2001-2007 Escape, Explorer Sport Trac2004 F-150 Heritage2004-2007
LINCOLN:1997-2002 Continental1997-2007 Town Car2000-2006 Lincoln LS2006 Zephyr2007 MKZ1998-2007 Navi
MERCURY:1997-2002 Cougar, Mystique1997-2005 Sable1997-2007 Grand Marquis2005-2007 Montego2006-2007 M

This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUEThe majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electr
ACTIONIf 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 h
> 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 1445

heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual,
b.
If leaks are found in the body of the heater core itself, and does not appear to be the result of physical dama
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a know
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
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 gro
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.
> 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 1446

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
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 a
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then rete
o.
If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by add
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when the
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE EL
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 T
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
> Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Cor
Heater Hose: All Technical Service BulletinsA/C - Heater Core Electrolysis/Leakage

TSB 06-21-19
10/30/06

SERVICE PROCEDURE
> 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 1452

b.
NOTE

> 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 1453

o.
NOTE
CAUTION
NOTE
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
> Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 1454
Heater Hose: Specifications

Heater Hose clamps .............................................................................................................................................................
> Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 1455
Heater Hose: Service and Repair
REMOVAL
1. Partially drain cooling system.2. Disconnect heater water hoses.
INSTALLATION
1. Apply Premium Cooling System Fluid E2FZ-19549-AA or equivalent meeting Ford specification ESE-M97B44-A
hoses.
2. Install new heater water hoses and hose clamps.3. Fill cooling system.
> Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 98-9-11 > May > 98 > A/C - Poor Perform
Hose/Line HVAC: Customer InterestA/C - Poor Performance/Thumping Noise
Article No.98-9-11
05/11/98
AIR CONDITIONING - POOR AIR CONDITIONINGPERFORMANCE AND/OR "THUMPING" NOISE FROM

^
NOISE - "THUMPING" NOISE FROM AIRCONDITIONING SYSTEM - VEHICLES BUILTTHROUGH 4/15/9
ISSUEThere may be poor A/C performance and/or a "thumping" noise coming from the A/C system on some vehicles.
ACTIONReplace the suction accumulator and suction hose assemblies. The new accumulator and hose moves the cycli
SERVICE PROCEDURE
1.
Verify the concern by listening for a thump during A/C compressor engagement and/or install pressure gauges an
2.
If no thump is present or pressures are within specifications, refer to the appropriate Service or Workshop Manua
3.
F8VZ-19867-BA Suction Hose

F8AZ-19C836-AA Suction Accumulator

980911A Replace Accumulator And 1.0 Hr.
If a thump is present or the A/C switch cycles off at pressures higher than 24 psi, replace the A/C suction accumu
Suction Line - IncludesDischarge, Evacuate,Recharge And Leak CheckSystem
DEALER CODING
CONDITION
BASIC PART NO. CODE
19E561 42
OASIS CODES: 208000, 208200, 208999, 702100, 702300

> Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 98-9-11 > May > 98 > A/C -
Hose/Line HVAC: All Technical Service BulletinsA/C - Poor Performance/Thumping Noise
Article No.98-9-11
05/11/98

^
SERVICE PROCEDURE
1.
2.
3.


DEALER CODING
CONDITION
BASIC PART NO. CODE
19E561 42
OASIS CODES: 208000, 208200, 208999, 702100, 702300

> Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 1469
Hose/Line HVAC: Specifications

A/C Hose Clamps ................................................................................................................................................................
> Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line
Hose/Line HVAC: Service and RepairA/C Discharge Hose/Line

Description Tool Number
(5/8 inch)Spring Lock coupling Disconnect Tool 412-038 (T83P-19623-C)
REMOVAL
1. Discharge the refrigerant from the A/C system following the recommended procedure and observing all safety pre
Conditioning/Service and Repair/Discharging and Recovery
2. Remove A/C pressure cut-off switch.3. Loosen nut retaining A/C compressor to condenser discharge line to stud o
INSTALLATION
1. With the protective caps installed, route the new refrigerant line.2. Remove protective caps then connect the A/C c
7-9 N.m(62-79 lb-in). Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231
17-23 N.m (13-16 lb-in)
3. Install nut retaining A/C compressor to condenser discharge line to stud on engine front cover. Tighten to .4. Insta
> Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line > Page 1472
Hose/Line HVAC: Service and RepairA/C Liquid Hose/Line

REMOVAL
2. Disconnect and remove the condenser to evaporator tube from between A/C evaporator core and A/C condenser co
Disconnect Tool 412-038 (T83P-19623-C).
INSTALLATION
1. With the protective caps installed, route the new refrigerant line.2. Remove protective caps then connect the conde
7-9N.m (62-79 lb-in). YN-12c refrigerant oil meeting Ford specification WSH-M1C231-B (refer to Spring Lock
3. Leak-test, evacuate and charge the refrigerant system following the recommended procedures and safety precautio
> Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line > Page 1473
Hose/Line HVAC: Service and RepairA/C Suction Hose/Line
(5/8 inch)Spring Lock coupling Disconnect Tool 412-038 (TS3P- 19623-C)

(1/2 inch)Spring Lock coupling Disconnect Tool 412-027 (T81P-19623-G2)
NOTE: Whenever a refrigerant line is replaced, it will be necessary to replace the suction accumulator/drier.
REMOVAL
2. Remove the A/C cycling switch.3. Disconnect and remove the evaporator to compressor suction line using Spring
412-027 (T81P-19623-G2).
INSTALLATION
1. With the protective caps installed, route the new refrigerant line.2. Remove protective caps then connect the evapo
Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B.
3. Install the A/C cycling switch.4. Leak-test, evacuate and charge the refrigerant system following the recommended
> Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Page 1474
Hose/Line HVAC: Tools and Equipment

Description Tool Number.................................................................................................................................................
(3/8 inch)
(1/2 inch)
(5/8 inch)
(3/4 inch)
Spring Lock coupling Disconnect Tool ....................................................................................................................... 412
> Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 98-25-8 > Dec > 98 > Ste
Noise On Right Turns
Power Steering Line/Hose: Customer InterestSteering Wheel - Vibration/Buzzing Noise On Right Turns
Article No.98-25-8
12/21/98
^
NOISE - "BUZZING" NOISE FELT IN STEERING WHEEL ON RIGHT TURNS AT LOW RPMS
^
VIBRATION - VIBRATION/"BUZZING" NOISE FELT IN STEERING WHEEL ON RIGHT TURNS AT LOW
LINCOLN-MERCURY:1996-98 GRAND MARQUIS, TOWN CAR
This TSB article is being republished in its entirety to provide information for model years 1996 and 1998 and to correc
ISSUEA vibration/"buzzing" noise may be heard or felt in the steering wheel on right turns at engine rpms between 590
ACTIONReplace the power steering pressure hose to dampen the noise and reduce the possibility of the concern. Refer
SERVICE PROCEDURE
VERIFY THE CONCERN
NOTE
THIS TSB ARTICLE ONLY APPLIES TO CROWN VICTORIA/GRAND MARQUIS WITHOUT POLICE PAC
1. Make sure the steering shaft is not in contact with any lines or other components.
2. Check the level of fluid in the reservoir.
3. Make sure there is no air in the power steering system.
4. If no problems are found, proceed to the Instruction Sheet included in the applicable repair kit for repair procedur
5.
For 1996 and 1997 model year vehicles, follow the Instruction Sheet included in the kit. For 1998 model year veh
The Power Steering Hose Kits are as follows:
1996 Model Year (F6AZ-3A719-AA):

^ One (1) Hose and Connector Assembly - High Pressure
^ One (1) Bolt - M6-1.00x12.5
^ One (1) Nut - M6x1.0
^ One (1) Instruction Sheet (SK F7AC-3F784-BB)
> Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 98-25-8 >
Dec > 98 > Steering Wheel - Vibration/Buzzing Noise On Right Turns > Page 1483

^ One (1) Bolt - M6-1.00x12.5
^ One (1) Nut - M6x1.0
^ One (1) Nut - M6x1.0
F6AZ-3A719-AA Power Steering Hose Kit (1996)

SUPERSEDES: 97-18-5
982508A Replace Power Steering 0.7 Hr.

Pressure Hose
DEALER CODING
CONDITION
BASIC PART NO. CODE
3A719 55
OASIS CODES: 303000, 702000, 702100, 703000, 703100

> Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 98-25-8 > D
Buzzing Noise On Right Turns
Power Steering Line/Hose: All Technical Service BulletinsSteering Wheel - Vibration/Buzzing Noise On Right T
Article No.98-25-8
12/21/98
^
^
SERVICE PROCEDURE
VERIFY THE CONCERN
NOTE
5.

^ One (1) Bolt - M6-1.00x12.5
^ One (1) Nut - M6x1.0
> Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose:
> 98-25-8 > Dec > 98 > Steering Wheel - Vibration/Buzzing Noise On Right Turns > Page 1489

^ One (1) Bolt - M6-1.00x12.5
^ One (1) Nut - M6x1.0
^ One (1) Nut - M6x1.0

SUPERSEDES: 97-18-5

Pressure Hose
DEALER CODING
CONDITION
BASIC PART NO. CODE
3A719 55
OASIS CODES: 303000, 702000, 702100, 703000, 703100

> Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Page 1490
Power Steering Line/Hose: Specifications

Pressure Hose
To Pump ...........................................................................................................................................................................
Return Hose
To Gear .............................................................................................................................................................................
Power Steering Line/Hose: Description and Operation
TheBetween the power

power steering steering
pressure andpressure hoseatorthe
return hose power steering
power return
steering pumphose
usesand the hose
O-ring sealsnut
at the quick connect fitting
- Between the hose nut and the cast iron steering gear housing or power steering pressure, return and pump outlet l
Power Steering Line/Hose: Testing and Inspection
- The power steering hoses use O-ring seals at the quick connect fittings. There are two possible leak points at the
- A leak might occur between the (power steering pressure hose or power steering return hose ) and the hose nut.
-
A leak might occur between the hose nut and the aluminum steering gear housing or power steering pressure, retu
> Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose Fittings, Pressure and Return Line at Gear and Pump
Power Steering Line/Hose: Service and RepairHose Fittings, Pressure and Return Line at Gear and Pump
If a leak occurs between the tubing and tube nut, replace the power steering pressure hose and power steering return ho
The following procedure should be used:

1. Check the steering gear housing fitting and power steering pump valve outlet fitting to determine which fitting is l
between power steering pressure hose nut and power steering pump valve outlet fitting.
CAUTION: To prevent damage, don not over tighten.
2. If the leak is between the power steering pressure hose nut and the steering gear housing or power steering pump v
34-46 Nm (26-33 ft. lbs.)make sure the nuts are tightened to at the steering gear.
3. If the leak continues or if the leak is between power steering pressure hose and the power steering pressure hose nu
pressure hose.
4. Unscrew the power steering pressure hose nut and inspect the Teflon seal. Always replace the Teflon seal when th
removed. To facilitate assembly of the new Teflon seal, a tapered shaft may be required to stretch the washer so i
5. The rubber O-ring at the pump cannot be serviced with this design. If leak is due to the O-ring, replace the power s
rubber O-rings at the steering gear are serviceable.
The power steering pump valve outlet fitting is fully engaged only when the power steering pressure hose bottoms in th
> Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose Fittings, Pressure and Return Line at Gear and Pump > Page 1496
Power Steering Line/Hose: Service and RepairHose Fittings, Pressure and Return, Seal Replacement
If a leak occurs between the tubing and the tube nut, replace the power steering pressure hose and the power steering re
16-24 Nm (12-18 ft. lbs.).1. Check to make sure the nuts are tightened to Do not overtighten.
2. If leak continues, inspect for the following conditions:

- Damaged O-ring.
- Cracked or damaged convolution of tube end and sealing surfaces
- Damaged sealing surface in valve housing (step which supports tube and O-ring)
16-24 Nm (12-17 ft. lbs.)3. Replace the O-ring. Also replace the pressure line or valve housing if indicated by the in
Power Steering Line/Hose: Service and RepairPressure Hose

REMOVAL
1. Disconnect battery ground cable. 2. Remove power steering pressure hose fitting at power steering pump reservoir
INSTALLATION
16-24 Nm (12-17 ft. lbs.).

16-24 Nm (12-17 ft. lbs.).
34-46 Nm (26-33 ft. lbs.).
1. Position power steering pressure hose and power steering return hose in vehicle.2. Connect power steering pressur
Power Steering Line/Hose: Service and RepairQuick Connect Power Steering Fitting Seal Replacement
34-46 Nm (26-33 ft. lbs.).

1. Check the fitting to determine whether the leak is between the tube and tube nut or between the tube nut and the po
If a leak occurs between the tubing and tube nut, replace the power steering pressure hose and tube nut. If a leak occurs
4. Unscrew the tube nut and inspect plastic seal washer. Always replace the plastic seal washer when the power steer
facilitate assembly of new plastic seal washer, a tapered shaft such as a teflon seal replacer set 211-D027 (D90P-
5. The rubber O-ring cannot be serviced with this design. If leak is due to the O-ring, replace the power steering pres

34-46 Nm (26-33 ft. lbs.).6. Connect tube nut and tighten to
The quick connect fitting may disengage if not fully assembled, if the snap ring is missing, or if the tube nut or the hose
If the fitting disengages, replace the power steering pressure hose. The fitting is fully engaged only when the power ste
> Maintenance > Hoses > Radiator Hose > Component Information > Testing and Inspection
Radiator Hose: Testing and Inspection
1. Inspect cooling system hoses and clamped hose connections for leaks or excessive deterioration. Service or replac
> Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower)
Radiator Hose: Service and RepairRadiator Hoses (Lower)

REMOVAL
1. Raise vehicle on hoist.2. Drain cooling system.3. Disconnect degas bottle return hose from degas bottle.
4. Remove three rear screws retaining lower splash shield to radiator support.5. Compress clamp tangs and remove lo
INSTALLATION
1. Position the clamps (clipless pop clamps are glued to hose) at least 5 mm (0.196 inch) from each end of hose. Coa
approved water-resistant sealer.
CAUTION: Make sure the clamps are beyond the bead and placed in the center of the clamping surface of the c
2. Compress clamp tangs and install lower radiator hose on water pump.3. Compress clamp tangs and install lower ra
> Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower) > Page 1505
Radiator Hose: Service and RepairRadiator Hoses (Upper)

REMOVAL
CAUTION:
Do not mix Standard (green) Coolant with Extended Life Coolant (orange). If this contamination occurs the service c
1. Remove battery.2. Drain cooling system. 3. Compress clamp tangs and disconnect upper radiator hose from radiat
INSTALLATION
CAUTION: Make sure the clamps are beyond the radiator tank connector bead and placed in the center of the clam
1. Position the clamps (clipless pop clamps are glued to hose) at least 5.0 mm (0.195 inch) from each end of the hose
an approved water-resistant sealer.
2. Compress clamp tangs and install upper radiator hose onto thermostat cover connection.3. Compress clamp tangs
> Maintenance > Fluids > Brake Fluid > Component Information > Specifications
Brake Fluid: Specifications
Hydraulic brake fluid color must conform with the requirements of Federal Motor Vehicle Safety Standard 116. Und
High Performance DOT3 Brake FluidFord Specification ESA-M6C25-A

> Maintenance > Fluids > Brake Fluid > Component Information > Testing and Inspection > Fluid Color
Brake Fluid: Testing and InspectionFluid Color
NOTE:
Brake fluid contaminated with a hydrocarbon / mineral based fluid (power steering or transmission fluid) can be de
TheFluid
colordiscoloration
of the fluid incan occur due
a normal to system
brake heat andin/ service
or aging.
can vary from its original color for many reasons. Sometim
-
Difference in fluid color of a two-compartment brake master cylinder reservoir can be due to the different operati
- Fluid discoloration can exist when different brands / shades of brake fluid are used in topping off during normal s
-
Fluid discoloration can occur through dissolution of color dye used on brake master cylinder internal springs in m
> Maintenance > Fluids > Brake Fluid > Component Information > Testing and Inspection > Fluid Color > Page 1512
Brake Fluid: Testing and InspectionFluid Level
Always check the fluid level in the master cylinder before performing the test procedures. If the fluid level is not to 4
> Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations
Coolant: Technical Service BulletinsEngine Coolant - Propylene Glycol Recommendations
Article No.01-23-6
11/26/01
ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLA
ENGINE COOLANT - PROPYLENEGLYCOL-BASED - FORD MOTOR COMPANYPOSITION ON PROPYLE
FORD:1989-1993 FESTIVA1989-1994 TEMPO1989-1997 PROBE, THUNDERBIRD1989-2002 CROWN VICTORI
LINCOLN:1989-1992 MARK VII1989-2002 CONTINENTAL, TOWN CAR1993-1998 MARK VIII2000-2002 LS19

MERCURY:1989-1994 TOPAZ1989-1997 COUGAR1989-2002 GRAND MARQUIS, SABLE1991-1994 CAPRI199
MERKUR:1989 SCORPIO, XR4TI
This article is being republished in its entirety to update the model year coverage.
ISSUEThis TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolant
ACTION
> Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 1517

Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford
Published information suggests that engine coolants made with propylene glycol may provide engine cooling performa
Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be m
Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engin
OTHER APPLICABLE ARTICLES: NONESUPERSEDES: 96-16-4WARRANTY STATUS: INFORMATION ONLY

> Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications
Coolant: Capacity Specifications

GENERAL SPECIFICATIONS
13.3 L (14.1 U.S. quarts)Cooling System Refill Capacities ...........................................................................................
> Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1520
Coolant: Fluid Type Specifications

COOLANT TYPE
...............................................................................................................................................................
Coolant Mixture with Water................................................................................................................................................
Warning: Do not mix coolant types. Check the owners manual or refer to your local dealer for the correct coolan
> Maintenance > Fluids > Coolant > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Coolant: Initial Inspection and Diagnostic Overview

Check engine coolant level in the degas bottle at least once a month.
With a cold engine, the engine coolant level must be maintained at or above the COLD FILL LEVEL mark.
At normal engine operating temperature, the engine coolant level should be above the COLD FILL LEVEL mark
If no engine coolant is observed in the degas bottle or when a coolant level change does not occur, check the syst
1. With the engine cold, remove the pressure relief cap and inspect the filler neck sealing gasket for foreign material.
Cleaning and Inspection. Rinse pressure relief cap in clean water.
The pressure relief cap used on this system is unique. Replace only with the proper pressure relief cap.
2. Replenish the engine coolant in the degas bottle and add coolant to degas bottle as required.3. Install the pressure r
A low engine coolant level in the radiator can cause poor heater and defroster performance. If this condition exist
Engine Coolant F6AZ-19544-AA (orange), or equivalent and water, fill degas bottle to indicated level and rep
c. Start the engine and run until the water thermostat opens.d. Observe the level of engine coolant in the degas bo
level by adding a 50/50 mixture of Ford Premium Cooling System Fluid E2FZ-19549-AA (green), Ford Exten
e. Check for leakage at the following locations:
- all hoses and hose connections
- radiator seams, radiator core and radiator draincock
- all cylinder block core plugs and drain plugs
- edges of all cooling system gaskets
- transmission fluid cooler fittings
- vehicle heating system components
- water pump
f. Examine oil level dipstick for evidence of engine coolant in engine oil.
g. Check radiator for evidence of oil in coolant. Install cooling system analyzer to assist in testing the cooling sys
recommended connections and testing procedures.
> Maintenance > Fluids > Coolant > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1523
Coolant: Component Tests and General Diagnostics

1. Check engine coolant for dirty or rusty appearance. Dirty or rusty coolant requires replacement to protect the cooli
damage. Replace the coolant.
NOTE: Use only a permanent-type coolant such as Ford Premium Cooling System Fluid E2FZ-19549-AA or eq
2. If coolant condition is satisfactory, check coolant concentration for proper protection level. Use a Rotunda Battery
or equivalent hydrometer for testing. Maintain a protection level of at least -30 C (-20 F) to preserve anti-rust cor
If concentration level is low, partially drain the cooling system by opening the radiator draincock or by partially r
> Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications
Fluid - A/T: Capacity Specifications
A/T Fluid Capacity ..............................................................................................................................................................
A/T Fluid Refill ...................................................................................................................................................................
NOTE: With engine at operating temperature, shift through all gears. Check fluid in PARK add fluid as needed.
> Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1528
Fluid - A/T: Fluid Type Specifications

Fluid Type ............................................................................................................................................................................
> Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1529
Fluid - A/T: Service Precautions

NOTE:
Do NOT use ANY non-approved automatic transmission fluid for an application specifying MERCON V OR MER
Care must be taken to use the correct fluid for the specific application. Be sure to check the container label to insure
> Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1530
Fluid - A/T: Service and Repair
Normal maintenance and lubrication requirements necessitate periodic automatic transmission fluid changes. If a ma
CAUTION: Use of a fluid other than specified could result in transmission malfunction and/or failure.
Refer to the vehicle certification label affixed to the LH front door lock face panel or door pillar for the transmission
When filling a dry transmission or torque converter, refer to Specifications for capacity. Check the fluid level.
Procedures for partial drain and refill, due to in-vehicle service operation, are as follows:1. Raise and suitably suppor
slowly.
28 - 30 Nm (21 - 22 ft. lbs.)
5. Drain the torque converter by removing the torque converter drain plug.6. After the torque converter has been drai
NOTE: Transmission oil pan to case gasket is reusable if not damaged.
9. Lower vehicle.
6.1 liters (6.5 quarts)
10. When filling a dry transmission and converter, start with a minimum of .11. Fill transmission to proper level using
V specification.
> Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications
Fluid - Differential: Capacity Specifications

Capacity With 7.5 Ring Gear ...............................................................................................................................................
Note:
Fill no higher than 1/4 to 9/16 inch below fill plug.
Traction-Lok differentials add 4 oz of friction modifier C8AZ-19B956-A or equivalent, meeting Ford specification EST
> Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1535
Fluid - Differential: Fluid Type Specifications

NOTE: Use the following fluids or an equivalent.
Rear Axle LubricantPart No. ...............................................................................................................................................

> Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Page 1536
Fluid - Differential: Service and Repair
1. Raise vehicle.2. Clean all dirt from area of axle housing cover.3. Drain rear axle lubricant by removing axle housin
4. Apply Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A or ESE-M4G1
38 - 52 Nm (28 - 38 ft. lbs.)and tighten axle housing cover bolts to .
CAUTION:
Make sure machined surfaces on both axle housing cover and rear axle housing are clean before installing the ne
NOTE: Axle housing cover must be installed within 15 minutes of the silicone rubber application or new silico
6 - 14 mm5. Add SAE 80W-90; Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specifica
(0.250 - 0.562 inch)
28 - 40 Nm (21 - 29 ft. lbs.) below bottom of fill hole. Add 118.2 ml (4 oz) of Additive Friction Modifier C8AZ-
> Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications
Engine Oil - Oil Recommendations/Applications
Article No.02-1-9
01/21/02
ENGINE - ENGINE OIL - RECOMMENDEDAPPLICATIONS FOR SAE 5W-20 AND SAE 5W-30MOTOR OILS -
FORD:1992-2002 CROWN VICTORIA1993-1994 TEMPO1993-1997 THUNDERBIRD1993-2002 ESCORT, MUST
LINCOLN:1991-2002 TOWN CAR1993-1998 MARK VIII1993-2002 CONTINENTAL2000-2002 LS1998-2002 NA
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
ISSUEFord Motor Company now recommends SAE 5W-20 viscosity grade for servicing most gasoline and flexible fu
ACTIONAll 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the recommended oil change
Testing has validated thisGRAND

MERCURY:1992-2002 viscosityMARQUIS1993-1994
grade can be used in many previous model
TOPAZ1993-1997 year vehicles. It is recommended
COUGAR1993-1999 ALL v
TRACER1993-2002
All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002 Vehicles" chart ar
> Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 1541

motor oil at the factory and should also be serviced with SAE 5W-20 oil.
Exception 2001 Vehicles
NOTE
IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED. REFER TO TS
Parts Block
OTHER APPLICABLE ARTICLES: 99-8-16SUPERSEDES: 01-4-7WARRANTY STATUS: INFORMATION ONLY

Veh. App. Listing Approved For SAE 5W-20 Motor Oil
^ 1993-1996 1.9L Escort/Tracer

^ 1995-2000 2.0L Zetec Contour/Mystique
^ 1999-2002 2.0L Cougar
^ 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

^
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
Engine Oil: Technical Service BulletinsMotor Oil - Viscosity Grade Recommendation
Article No.99-8-16
05/03/99
MOTOR OIL - SAE VISCOSITY GRADERECOMMENDATION - SERVICE TIP
LINCOLN-MERCURY:1989-1992 MARK VII1989-1994 TOPAZ1989-1997 COUGAR1989-1999 CONTINENTAL,
LIGHT TRUCK:1989-1990 BRONCO II1989-1996 BRONCO1989-1997 AEROSTAR, F SUPER DUTY1989-1999 E
ISSUEFord Motor Company now recommends SAE 5W-30 viscosity grade for servicing any Ford gasoline-powered v
ACTIONWhen servicing any Ford gasoline-powered vehicle, use SAE 5W-30 viscosity grade motor oil. Refer to the fo
Both SAE 10W-30 and SAE 5W-30 viscosity grade motor oils have been recommended in the past depending on vehic
Tests have proven SAE 5W-30 viscosity grade motor oil provides the optimum protection and benefits for Ford gasolin
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
XO-5W30-QSP 5W-30 Motorcraft Super Premium Motor Oil

> Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications
Engine Oil: Capacity Specifications
Engine Oil
Capacity ...............................................................................................................................................................................
NOTE: Listed capacities are approximate. Check fluid level after filling.
> Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1547
Engine Oil: Fluid Type Specifications
Engine Oil Type
Type .....................................................................................................................................................................................
Viscosity .............................................................................................................................................................................
NOTE: Must meet Ford Specification M2C-153-F

> Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage
Power Steering Fluid: Technical Service BulletinsSteering - Mercon V(R) Fluid Usage
TSB 07-1-7
01/22/07
MERCON(R) ATF REPLACED BY MERCON(R) V AS ASERVICE FLUID FOR SOME POWER STEERINGSYST
FORD:1996-1997 Thunderbird1996-2007 Crown Victoria, Mustang, Taurus1998-2003 Escort2000-2007 Focus2002-2
LINCOLN:1996-1998 Mark VIII1996-1999 Continental1996-2007 Town Car2000-2006 Lincoln LS2006 Zephyr2007

MERCURY:1996-1997 Cougar1996-2005 Sable1996-2007 Grand Marquis1999-2002 Cougar2003-2004 Marauder200
ISSUEMERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power s
> Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 1552

ACTIONBeginning immediately all power steering applications requiring MERCON(R) can now be serviced using ME
SERVICE PROCEDURE
Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmissio
CAUTION
APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLU
Parts Block
Disclaimer
> Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications
Power Steering Fluid: Capacity Specifications

Fill to line in power steering fluid reservoir.
> Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 1555
Power Steering Fluid: Fluid Type Specifications

FLUID TYPE ........................................................................................................................................................... Ford
> Maintenance > Fluids > Power Steering Fluid > Component Information > Service and Repair > Fill Procedures
Power Steering Fluid: Service and RepairFill Procedures
Start-Up Procedure (After Service)

Part 1 Of 2
> Maintenance > Fluids > Power Steering Fluid > Component Information > Service and Repair > Fill Procedures > Page 1558

Part 2 Of 2
DESCRIPTION
This procedure is recommended whenever the power steering pump or power steering short rack is replaced.
MATERIALS REQUIRED
The101 kPa (30materials

following in. Hg). are required:-
A vacuum pump with gauge, capable of pulling The vacuum source should be a Rotunda Vacuum Tester 014
-
A No.7 stopper cap or a special power steering reservoir cap assembly with a tee connection, shutoff valves a
PREPARATION
1. Assemble the vacuum fill system.2. Install the vacuum fill system on the vehicle. If the power steering short rack o
to drain from the system.
3. Tighten all steering system and vacuum fill connections to specification. Do not over tighten or damage may resul
INITIAL FILL
1. Install the rubber stopper on power steering pump reservoir.2. Open valve No. 1 and allow the power steering fluid
steering pump reservoir.
84-101 kPa (25-30 in. Hg)

3 kPa (14. Close all valves.5. Open valves No. 3 and No. 5. Start the vacuum pump. Operate the pump until a gauge
in. Hg), there is a leak in the power steering or filling system that must be corrected.
84-101 kPa (25-30 in. Hg)
7. Startle vacuum pump. Open valve No. 5. Operate the pump until a gauge reading of is obtained.8. Close valve No
higher than the power steering pump and power steering pump reservoir.
9. When fluid stops draining from vacuum fill reservoir, close valve No.1 and remove cap or rubber stopper.
FINAL FILL
1. Adjust fluid level in power steering pump reservoir to correct level. There will be a slight drop in the level when th
steering wheel cycled.
2. Operate the engine at an idle for 15 minutes, then inspect for leaks. It will not be necessary to devac the system un
the power steering pump that could cause noise or affect performance.
Top Off
74-79C (165-175F). 1. Idle engine for two to three minutes to warm fluid to 2. Turn steering wheel all the way to the
CAUTION: Do not overfill power steering pump reservoir.

3. Check fluid level(ATF)
Multi-Purpose in theTransmission
power steering pump reservoir. Fluid level should be between the MIN and MAX marks. I
Fluid.
> Maintenance > Fluids > Power Steering Fluid > Component Information > Service and Repair > Fill Procedures > Page 1559
Power Steering Fluid: Service and RepairFlushing

DESCRIPTION
Always flush the power steering system when replacing any component due to fluid contamination. Also flush th
PROCEDURE
1. Place the oil cooler-to-reservoir hose at remote reservoir in a container and plug the power steering return line clam
may be used.
2. Fill the vehicle remote power steering reservoir with MERCON(r) Multi-Purpose (ATF) Transmission Fluid.3. Di
the START position and crank the engine with the starter motor while turning the steering wheel from left to righ
5. When all the fluid has been added, turn ignition switch to the OFF position.6. Remove the plug from the power ste
7. Check fluid level. Add fluid if necessary.8. Crank engine and recheck fluid level. Add fluid as necessary.9. Lower
10. Start engine and turn steering wheel slowly from lock-to-lock several times. Check fluid level and adjust as requir
> Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants
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 LTD1985-1988 EXP1985-1994 TEMPO1985-1997 THUNDERBIRD1985-2000 CROWN VICTOR
LINCOLN:1985-1992 MARK VII1985-2000 CONTINENTAL, TOWN CAR1993-1998 MARK VIII2000 LS1998-20

MERCURY:1985-1986 MARQUIS1985-1987 LYNX1985-1994 TOPAZ1985-1997 COUGAR1985-2000 GRAND M
MERKUR:1985-1989 XR4TI 1988-1989 SCORPIO
> Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1564

This TSB article is being republished in its entirety to add model year vehicles
ISSUEA number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop
ACTIONRefrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to pre
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 M
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 Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Li
The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditionin
The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity p
The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyz

when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/
Recovery of Contaminated Refrigerant
If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling e
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
3.
Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing
Repairing A Contaminated A/C System
Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommen
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 a
^ 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

^ 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

Article No.98-12-5
06/22/98

ACTION

SUPERSEDES: 96-15-5

(R-12) Recovery
DEALER CODING
CONDITION
BASIC PART NO. CODE
19703 49
OASIS CODES: 208000, 208999
Service Procedure
CAUTION
NOTE

CAUTION
1.
3.
CAUTION
4.

b.
NOTE:
8.
CAUTION
^
9.
11.

13.
NOTE:

F73Z-19577-AA
F7AZ-19589-DA
NOTE
> Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications
Refrigerant: Capacity Specifications
Refrigerant Capacity ............................................................................................................................................................

> Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1574
Refrigerant: Fluid Type Specifications

Refrigerant Type ..................................................................................................................................................................
> Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications
Refrigerant Oil: Capacity Specifications
Oil Capacity .........................................................................................................................................................................

> Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1579
Refrigerant Oil: Fluid Type Specifications

Polyalkylene Glycol (PAG) ........................................................................................................................................ WSH
> Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1580
Refrigerant Oil: Service and Repair
The A/C compressor uses a special refrigerant oil, PAG Compressor Oil F7AZ-19589-DA or Motorcraft YN-12c or eq
It is important that only the specified type and quantity of refrigerant oil be used in the A/C compressor. If there is surp
DURING A/C COMPRESSOR REPLACEMENT
Whenever the A/C compressor is replaced and evidence of debris is present within the A/C system, the following must
- replace suction accumulator/drier
- replace the A/C evaporator core orifice
- clean the A/C system by flushing or filtering
NOTE: Service A/C compressors are shipped without compressor oil.
When reinstalling the existing A/C compressor or installing a new A/C compressor, the A/C compressor must be servic
1. Obtain a clean container that can also be used as a measuring device.2. Place the A/C clutch on the A/C compresso
89 and 142 ml (3 and 5 ounces) 30 ml (13. Rotate the shaft by hand six to eight revolutions, collecting the oil in a c
ounce)
of clean PAG Compressor Oil F7AZ-19589-DA or Motorcraft YN-12c or equivalent meeting Ford specification
142 ml (5 ounces)5. If the amount of oil that was removed from the old A/C compressor is greater than , pour the sam
Compressor Oil F7AZ-19589-DA or Motorcraft YN-12c or equivalent meeting Ford specification WSH-M1C231
89 ml (3 ounces) 89 ml (3 ounces)6. If the amount of refrigerant oil that was removed from the old A/C compressor
> Maintenance > Brake Bleeding > System Information > Service Precautions
Brake Bleeding: Service Precautions
When any part of the hydraulic system has been disconnected for service or replacement, air may enter the system ca
> Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure
Brake Bleeding: Service and RepairCaliper Bleeding Procedure
1. Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the disc brake calipe
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 ca
Repeat
tighten the until clear, caliper
disc brake bubble-free fluid
bleeder comes out.
screw.-
- Refill the brake master cylinder reservoir as necessary.
4. Tighten the disc brake caliper bleeder screw.
> Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 1586
Brake Bleeding: Service and RepairManual Bleeding
The primary and secondary (front and rear) hydraulic brake systems are individual systems and are bled separately. B
NOTE:
Non-ABS vehicles have the brake master cylinder mounted at an angle. Bleeding may be better performed if the ve
1. To bleed the brake system, position a suitable box wrench on the bleeder fitting on the caliper bleeder fitting. Atta
bleeder fitting. The end of the tube should fit snugly around the bleeder fitting.
2. Submerge the free end of the tube in a container partially filled with clean brake fluid and loosen the bleeder fittin
of a turn.
3. Have an assistant push the brake pedal down slowly through its full travel. Close the bleeder fitting; then return th
position. Repeat this operation until air bubbles cease to appear at the submerged end of the bleeder tube.
4. When the fluid is completely free of air bubbles, secure the bleeder fitting and remove the bleeder tube.5. Repeat t
bled and install the master cylinder cap and gasket. Make sure the diaphragm-type gasket is properly positioned i
6. If the primary (front brake) system is to be bled, repeat Steps 2 through 5 at the RH front brake caliper and ending
seated. This is accomplished by applying the brake pedal several times until normal pedal travel is established.
Brake Bleeding: Service and RepairMaster Cylinder Bleeding
When a new brake master cylinder has been installed or the brake system has been emptied or partially emptied, fluid
CAUTION:
Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, im
2. Install short brake tubes in the brake master cylinder and position them so that they point back into the reservoir an
submerged in brake fluid.
3. Fill the reservoir with new Ford High Performance DOT-3 Motor Vehicle Brake Fluid C6AZ-19542-AB or DOT-
specification ESA-M6C25-A.
4. Cover the reservoir with a clean shop towel.5. Pump the brakes until clear, bubble-free fluid comes out of both bra
a. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the brake pedal.b. Loosen the
brake pedal until the brake tube fitting is tightened again.
c. Repeat this operation until clear, bubble-free fluid comes out from around the tubing fitting.d. Repeat this blee
8. If any of the brake tubes or calipers have been removed, it may be helpful to prime the system by gravity bleeding
brake master cylinder is primed and bled.To prime the brake system:a. Fill the brake master cylinder reservoir wi
meeting Ford specification ESA-M6C25-A.
b. Loosen both rear caliper bleeder screws and leave them open until clear brake fluid flows out. Do not let brake
dry, check it often.
c. Tighten the bleeder screws.d. One at a time, loosen the front caliper bleeder screws. Leave the bleeder screws o
cylinder reservoir run dry, check it often.
8 - 20 Nm (71 - 177 inch lbs.)e. Tighten the bleeder screws to .
9. After the brake master cylinder has been primed, the lines bled at the brake master cylinder and the brake system p
bleeding can resume at each wheel.
Brake Bleeding: Service and RepairPressure Bleeding
69 - 206 kPa (10 - 30 psi)For pressure bleeding, use a bladder-type bleeder tank only, such as Rotunda Brake Bleed
CAUTION: 344 kPa (50 psi) Never exceed pressure or damage to brake system can occur.
1. Clean all dirt from the master cylinder reservoir cover.2. Remove the brake master cylinder reservoir cover. Fill th
adapter tool to the brake master cylinder and attach the bleeder tank hose to the fitting on the adapter. Master cyli
3. If the rear disc brake calipers (the secondary brake system) are to be bled, use a suitable box wrench on the bleede
brake caliper. Attach a bleeder tube snugly around the bleeder fitting.
4. Open the valve on the bleeder tank to admit pressurized brake fluid into the brake master cylinder reservoir.5. Sub
dust cap on bleeder screw.
7. Attach a bleeder tube and repeat Steps 4,5 and 6 at the LH rear caliper.8. On front brakes, repeat Steps 4, 5 and 6 s
10. After disc brake service, make sure disc brake pistons are returned to their normal positions and the pad, pad and l
seated. This is accomplished by depressing the brake pedal several times until normal pedal travel is established.
11. Remove the pressure bleeder adapter tool from brake master cylinder. Fill the brake master cylinder reservoir to b
(0.16 inch) below MAX line. Install the brake master cylinder filler cap.
Brake Bleeding: Service and RepairWith ABS
(NGS)
(NGS)Anytime service is performed on the ABS valve block or pump and motor assembly, a special bleed procedure
trouble codes.
3. Make sure ignition switch is in the RUN position.4. Follow instructions on the NGS screen:
- Choose correct vehicle and model year
- Select "Diagnostic Data Link" menu item
- Select ABS Module
- Select "Function Tests"
- Select "Service Bleed"
5. The NGS will prompt you to apply the brake pedal. Make sure you push hard on the brake pedal. You will need to
approximately 5 seconds while the NGS opens the outlet valves in the brake pressure control valve block. When
6. Repeat Step 5 to make sure all air is flushed from the ABS unit. Upon completion, the NGS will display "Service B
> Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming
Air Bag(s) Arming and Disarming: Service and RepairArming and Disarming
Deactivation Procedure
1. Record USER 1 and USER 2 preset radio frequencies for reprogramming following completion of service procedu

one minute (ECS)3. Wait for backup power supply in air bag Electronic Crash Sensor module to deplete stored ene
4. Remove driver air bag module from vehicle.
WARNING:^
CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN.
5. Connect Rotunda Air Bag Simulator 105-R0012 or equivalent to vehicle harness at top of steering column.
6. Remove passenger air bag module. Install Rotunda Air Bag Simulator 105-R0012 or equivalent on vehicle harness
air bag module.
Reactivation Procedure
WARNING: THE AIR BAG SIMULATOR MUST BE REMOVED AND THE AIR BAG RECONNECTE
one minute (ECS)

2. Wait for backup power supply in air bag Electronic Crash Sensor module to deplete stored energy.3. Remove Ro
WARNING:^
WARNING: CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTE
5. Remove Rotunda Air Bag Simulator 105-R0012 or equivalent from vehicle harness connector on passenger side. R
air bag module.
6. Reconnect battery ground cable.7. Prove out system.

> Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 1594

8. Reprogram USER 1 and USER 2 preset radio frequencies and set clock.
> Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 1595
Air Bag(s) Arming and Disarming: Service and RepairAir Bag System Reconnect Checklist
The check list should be completed following diagnosis or service of any air bag system concern:
1. Are all crash sensors connected and mounted to the vehicle? .....................................................................................
2. Is three-way connector at base of steering column connected? ...................................................................................
3. Are the air bags or air bag simulators connected? .......................................................................................................
(ECS)4. Is air bag electronic crash sensor module connected? ......................................................................................
5. Is vehicle battery connected? .......................................................................................................................................

> Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions
Circuit Breaker: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1601


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
Circuit Breaker: Electrical Diagrams
Circuit-to-Circuit Breaker Cross Reference
For wiring diagrams, please refer to Starting and Charging/Power and Ground Distribution/Diagrams/Electrical/Power
Circuit Breaker 7
Circuit Breaker 17
Circuit Breaker 12
Circuit Breaker 14
> Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions
Fuse: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1613


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
Fuse: Electrical Diagrams
Circuit-to-Fuse Cross Reference
(PCM)
Air
FuseSuspension
1 System ........................................................................................................................................................
Fuse 1 - protects the following circuits:
^ Electric Fuel Pump Relay

Power Distribution
Fuse 2
^ Starter Relay
^ Generator
^ Fuse 15
^ Fuse 18

Power Distribution
Fuse 3
^ Radio
^ Subwoofer Amplifier
^ Compact Disc Changer

Power Distribution
Fuse 4
^ Police Power Relay

Power Distribution
Fuse 5
^ Horn Relay

Power Distribution
Fuse 6
^ Daytime Running Lamp Module

Power Distribution
Fuse 8
^ Air Suspension System

Power Distribution
Fuse 9
^ Fuse 5
^ Fuse 9

Power Distribution
Fuse 10
^ Fuse 1
^ Fuse 2
^ Fuse 6
^ Fuse 7
^ Fuse 10
^ Fuse 11
^ Fuse 13
^ Circuit Breaker 14

Power Distribution
Fuse 11
^ Fuse 4
^ Fuse 8
^ Fuse 16

Power Distribution
Fuse 12
^ (PCM)Powertrain Control Module
^ PCM Power Relay

Power Distribution
Fuse 13
^ High Speed Cooling Fan Relay

Power Distribution
Fuse 14
^ Rear Window Defrost Relay
^ Fuse 17

Power Distribution
Fuse 15
^ Anti-Lock Brake Module

Power Distribution
Fuse 16
^ Police Option Fuse Holder

Power Distribution
A/C-Heater Mode Switch.....................................................................................................................................................


Blower
Fuse 1 Motor........................................................................................................................................................................
^ Multi-Function Switch
^ Brake Pedal Position Switch
^ Speed Control

Power Distribution

Power Distribution
Fuse 2
^ Wiper Control Module
^ Windshield Wiper Motor

Power Distribution

Power Distribution
Fuse 4
^ Lighting Control Module
^ Main Light Switch

Power Distribution

Power Distribution

Power Distribution
Fuse 5
^ Backup Lamps
^ Variable Assist Power Steering
^ Turn Signals
^ Air Suspension
^ Daytime Running Lamps
^ Speed Chime Warning

^ Electronic Day/Night Mirror
^ Shift Lock
^ Electronic Automatic Temperature Control
Power Distribution

Power Distribution
Fuse 6
^ Speed Control
^ Main Light Switch
^ Clock

Power Distribution

Power Distribution

Power Distribution
Fuse 7
^ Powertrain Control Module
^ Power Diode
^ Ignition Coils

Power Distribution

Power Distribution
Fuse 8
^ Power Mirrors
^ keyless Entry
^ Clock Memory
^ Passive Anti-Theft System Module

^ Power Windows
^ Police Spot Lamps
Power Distribution

Power Distribution
Fuse 9
^ Blower Motor
^ A/C-Heater Mode Switch

Power Distribution

Power Distribution
Fuse 10
^ Air bag Module

Power Distribution

Power Distribution
Fuse 11
^ Radio

Power Distribution

Power Distribution
Fuse 13
^ Warning Lamps
^ Analog Cluster Gauges and Indicators

Power Distribution

Power Distribution

Power Distribution
Fuse 15
^ Anti-Lock Brake System
^ Instrument Cluster
^ Transmission Control Switch

Power Distribution

Power Distribution
Fuse 16
^ Cigar Lighter

Power Distribution

Power Distribution
Fuse 17
^ Rear Defrost

Power Distribution

Power Distribution
Fuse 18
^ Air Bag Module

Power Distribution

Power Distribution
> Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
Fuse Block: Locations

Engine View
The Engine Compartment Fuse Box is located at the RH front of the engine compartment, behind battery.
> Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1675


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
Fuse Block: Electrical Diagrams


Instrument Panel Fuse Panel
Air Suspension System ........................................................................................................................................................


(PCM)
Fuse 13 .................................................................................................................................................................................
Fuse 1

Power Distribution
Fuse 2
^ Starter Relay
^ Generator
^ Fuse 15
^ Fuse 18

Power Distribution
Fuse 3
^ Radio

Power Distribution
Fuse 4

Power Distribution
Fuse 5
^ Horn Relay

Power Distribution
Fuse 6

Power Distribution
Fuse 8

Power Distribution
Fuse 9
^ Fuse 5
^ Fuse 9

Power Distribution
Fuse 10
^ Fuse 1
^ Fuse 2
^ Fuse 6
^ Fuse 7
^ Fuse 10
^ Fuse 11
^ Fuse 13

Power Distribution
Fuse 11
^ Fuse 4
^ Fuse 8
^ Fuse 16

Power Distribution
Fuse 12
^ PCM Power Relay

Power Distribution
Fuse 13

Power Distribution
Fuse 14
^ Fuse 17

Power Distribution
Fuse 15

Power Distribution
Fuse 16

Power Distribution


Blower
Fuse 1 Motor........................................................................................................................................................................
^ Speed Control

Power Distribution

Power Distribution
Fuse 2

Power Distribution

Power Distribution
Fuse 4
^ Main Light Switch

Power Distribution

Power Distribution

Power Distribution
Fuse 5
^ Backup Lamps
^ Turn Signals
^ Air Suspension

^ Shift Lock
Power Distribution

Power Distribution
Fuse 6
^ Speed Control
^ Main Light Switch
^ Clock

Power Distribution

Power Distribution

Power Distribution
Fuse 7
^ Power Diode
^ Ignition Coils

Power Distribution

Power Distribution
Fuse 8
^ Power Mirrors
^ keyless Entry
^ Clock Memory

^ Power Windows
^ Police Spot Lamps
Power Distribution

Power Distribution
Fuse 9
^ Blower Motor

Power Distribution

Power Distribution
Fuse 10
^ Air bag Module

Power Distribution

Power Distribution
Fuse 11
^ Radio

Power Distribution

Power Distribution
Fuse 13
^ Warning Lamps

Power Distribution

Power Distribution

Power Distribution
Fuse 15

Power Distribution

Power Distribution
Fuse 16
^ Cigar Lighter

Power Distribution

Power Distribution
Fuse 17
^ Rear Defrost

Power Distribution

Power Distribution
Fuse 18
^ Air Bag Module

Power Distribution

Power Distribution
> Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions
Fusible Link: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1738


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
Fusible Link: Electrical Diagrams

Fuse Link - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse b
Power Distribution
> Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > High Current Relay Center
> Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > High Current Relay Center > Page 1750
Relay Center (C110)

> Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation
Malfunction Indicator Lamp: Description and Operation
During vehicle operation. the malfunction indicator lamp (MIL) (SERVICE ENGINE SOON) illuminates when the p
> Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Pr
Recall - Vehicle Jacking Procedure
SAFETY RECALL00S13
Certain Crown Victoria, Grand Marquis, and Lincoln Town Car - Vehicle Jacking Procedure.
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIIÎnformation
Attachment

> Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall -
Vehicle Jacking Procedure > Page 1764

OASISYou 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
PROMPTLY CORRECT
Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated C

DEALER-OWNER CONTACT
Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and
REGIONAL CONTACTAdvise regional office if an owner:
^ cannot be contacted.
^ does not make a service date.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
RENTAL CARSRental vehicles are not approved for this program.
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts Ordering Information
An owner guide supplement, a jack operating instruction label, a revised jack usage and stowage label, and a jack usage
Additional owner packages containing the above mentioned items can be ordered by calling the Recall Hotline at 1-800
OVERVIEWThere are four (4) items revising the jacking instructions that must be placed in the vehicle:
^ Tire Change Procedure Supplement.
^ Jack Operating Instructions label.

^ Jack Usage and Stowage label.
^ Jack Usage and Stowage/Tire Changing Instruction placard.
The following instructions/illustrations will help locate the proper area for each of these items.
TIRE CHANGE PROCEDURE SUPPLEMENT PLACEMENT

1. Insert the new tire change procedure supplement into the vehicle owner's guide, which is located in the glove com
JACK OPERATING INSTRUCTIONS LABEL PLACEMENT
NOTE:
The jack may be located under the spare tire or behind the right quarter trim panel.
1. Locate the jack by either removing the spare tire cover and spare tire (if equipped), or by removing the right quar

2. Install the Jack Operating Instructions label onto the jack as illustrated. See Figure 2.
JACK USAGE AND STOWAGE LABEL PLACEMENT
NOTE:
The Jack Usage and Stowage label may be located on the inner right quarter panel or the underside of the spare tire
1.
Locate the original Jack Usage and Stowage label. Then install the new Jack Usage and Stowage label directly ov
JACK USAGE AND STOWAGE/TIRE CHANGING INSTRUCTIONS PLACARD PLACEMENT

1.
Install the spare tire, if removed. Then place the new Jack Usage And Stowage/Tire Changing Instruction placard
2. Install the spare tire cover (if equipped) and/or the right quarter trim panel, if removed.


> Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Rec
SAFETY RECALL00S13
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
Attachment

> Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 >
Jul > 00 > Recall - Vehicle Jacking Procedure > Page 1776

PLEASE NOTE
PROMPTLY CORRECT

LABOR ALLOWANCES
PARTS REQUIREMENTS


NOTE:

NOTE:
1.

1.


> Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 1783
Vehicle Lifting: Description and Operation
WARNING: ON VEHICLES EQUIPPED WITH AIR SUSPENSION, THE ELECTRICAL POWER SUPPLY
CAUTION:
Do not allow the hoist adapters to contact the steering linkage, suspension arms, stabilizer bar, or to compress the low
If a two-post hoist is used to lift a vehicle, place the adapters under the front suspension lower arms.
Hoist, Drive On
To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on hoist without first check
Hoist, Frame Contact
WARNING: WHEN HOISTING AT LIFT POINTS, ESPECIALLY FRONT LIFT POINTS, BE CAREF
CAUTION:
- All four contact points must contact the adapters.
- Never use the differential housing as a lift point (applies to all rear wheel drive vehicles).
NOTE: Before hoisting the vehicle, verify that there is sufficient clearance between the hoist and the exhaust sy
Vehicle Lift Points
On frame contact hoists, adapters are necessary to lift the vehicle. The adapters must be placed at four contact po
Exercise care when hoisting vehicles equipped with catalytic converter(s). On vehicles so equipped, verify necess
Vehicles with unitized body-frame construction require special precautions and procedures when the vehicle is ja
Hoist, Twin Post To ensure safe hoisting, the front post adapters must be positioned carefully to contact the cent
Jack, Floor
WARNING: NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND.
CAUTION:

-
The service jack provided with the vehicle is only intended to be used in an emergency for changing a def
- Do not attempt to use jack pressure on either the front bumper or the rear bumper of any unitized vehicle.
- Care must be exercised not to contact the steering linkage or to compress the lower suspension arm stabili
- Never use the differential housing as a lift point.
When using a floor jack, the vehicle may be raised at several locations. The front of the vehicle may be lifted by
Position jacks under the rear axle housing tubes between the suspension arm brackets and the differential housing
Vehicle Lifting: Service and Repair
CAUTION:
Hoist, Drive On
CAUTION:
Vehicle Lift Points
Jack, Floor
CAUTION:

-
> Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Recalls for Spare Tire: > 98B20 > Jun > 98 > Recall - Mini-Spare/Traction
Recall - Mini-Spare/Traction Control Problem

98520
Traction Control Performance With Mini-Spare Tire Installed
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIII^
^
New PartIV^
Attachment Procurement Process of Low Volume Recalls

> Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Recalls for Spare Tire: > 98B20 > Jun > 98 > Recall -
Mini-Spare/Traction Control Problem > Page 1796


OASISOwners will receive a notification letter that instructs them to call a toll-free number to arrange for parts to be sh
LOW VOLUME RECALLS AND OWNER NOTIFICATION PROGRAMSThis recall is being processed as a Low V
DEALER-OWNER CONTACTAfter receiving the MORS II contact, you are requested to contact the owner and arran
PLEASE NOTE
Correct all vehicles in stock before delivery.
You must contact the Low Volume Recall Coordination Center at 1-800-248-0186 to arrange for parts if you have an in
PROMPTLY CORRECT
^ Affected vehicles on the enclosed list.

REGIONAL CONTACTAdvise regional office if:
^ an owner cannot be contacted.
^ an owner does not make a service date.

Program Code - 98B20Misc. Expense - REFUNDMisc. Expense - ADMIN.Misc. Expense - 0.2 Hr.
LABOR ALLOWANCES
PARTS REQUIREMENTSParts will be shipped to your dealership according to the procedures established for "Low V
^ DOES II
EXCESS STOCK RETURNExcess stock returned for credit must have been purchased from Ford Customer Service D
CLAIMS PREPARATION
^ Enter using DWE.
^ Use code information shown below:
Program Code - 98B20Labor Operation - See above

ABS MODULE REPLACEMENT
AFFECTED VEHICLES:1998 CROWN VICTORIA, GRAND MARQUIS AND TOWN CAR EQUIPPED WITH TR
SERVICE PROCEDURE

2. Disconnect ABS module electrical connectors. Refer to Figure 1.
3. Remove four (4) retainers securing ABS module to Hydraulic Control Unit (HCU). See Figure 1.
4. Remove ABS module from vehicle.
5. Install new ABS module into vehicle.
6. Install four (4) retainers securing ABS module to Hydraulic Control Unit (HCU). Tighten retainers to 1.8-2.8 Nm
7. Connect ABS module electrical connectors.
8. Connect battery negative cable, then remove memory saver.


9. Reflash Powertrain Control Module (PCM). Refer to SBTS for PCM calibrating procedure. Use calibration code
AUTHORIZED MODIFICATIONS LABEL
^
Obtain, prepare and attach the Authorized Modifications Label. Write in the modification description, your P &




> Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spare Tire: > 98B20 > Jun > 98 > Reca
Problem

98520
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIII^
^
New PartIV^

> Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spare Tire: > 98B20 >
Jun > 98 > Recall - Mini-Spare/Traction Control Problem > Page 1810


PLEASE NOTE
PROMPTLY CORRECT


LABOR ALLOWANCES
^ DOES II
CLAIMS PREPARATION
^ Enter using DWE.

SERVICE PROCEDURE



^




> Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Page 1819
Spare Tire: Specifications
Wheel Size ...........................................................................................................................................................................

> Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Service Precautions > Customer Safety Information
Spare Tire: Customer Safety Information

- Do not exceed the recommendations of load rating capacity specified on the vehicle safety certification decal loca
- A jack is provided for wheel and tire maintenance only.
- Never run engine when vehicle is supported by a jack.
> Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Service Precautions > Customer Safety Information > Page 1822
Spare Tire: Vehicle Damage Warnings
WARNING: NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, SUCH AS WHEN CHA
NOTE:
Extended use of other than conventional spare tires on a Traction-Lok rear axle could result in a permanent reduction
> Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment
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 THUNDERBIRD1997-2000 CONTOUR1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAUR

LINCOLN:
1997-1998 MARK VIII1997-2002 CONTINENTAL, TOWN CAR2000-2002 LS1998-2002 NAVIGATOR2002 BLA
MERCURY:1997 COUGAR1997-2000 MYSTIQUE1997-2002 GRAND MARQUIS, SABLE1999-2002 COUGAR19
ISSUEThe purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equ
This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. Th
ACTIONThe Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel
Service Information
NOTE
TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES
NOTE
WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTE
> Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 1827

NOTE
UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPAB
1.
Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The
2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speed
NOTE
THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING T
3.
Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement ca
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 PAS
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 proce
e. The following items may contribute to an assembly centering verification FAILURE.
6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode.
Article No.99-11-1
06/14/99
^
^
CONTENTS

GENERAL PROCEDURES
Diagnostic Theory

Diagnostic Process

Glossary of Terms

Dynamic Balance







a.
c.
d.

-
Vibrate Software(R)

ChassisEAR
EngineEAR


Tracing Powder
d.

Diagnostic Process




2. Pre-Drive Check
important
^
^
^
^
5. Road Test
Note:
^

speed-related.
^
^
^

^

Steering Input Test
^
Brake Test
^
^
^
^

^ WARNING:
^ CAUTION:

^
WARNING:
CAUTION:
Note:
^
^ Start the engine.
^ CAUTION:

1. Static operation
^
2. While cranking
3. At idle
^
^
1.
1. Speed related
-
-
-

-

-
-
Airvaries
Noise Leak with
wind/vehicle
2. Acceleration
-
4. Braking.
^
^
^
5. Clutching

6. Shifting
^
8. Cruising speeds
1.




































Pinpoint Tests































1. Open the hood.
2. Note:
Note:
4.
3. CAUTION:

3.
6.
7.

^

^


WARNING:
4. CAUTION:

WARNING:
WARNING:
Note:
1. WARNING:

CAUTION:
6.
^

Wheel Bearing Check
1. WARNING:

2. Note :

^
> Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1924
Wheels: Specifications
Bolt Circle ............................................................................................................................................................................
Per Wheel .........................................................................................................................................................................
Lugs ......................................................................................................................................................................................
Steel ..................................................................................................................................................................................
Runout, Max
Radial ...............................................................................................................................................................................
Size .......................................................................................................................................................................................
> Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1925
> Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > Front
Wheels: Description and OperationFront
A front
Each sealedwheel
frontiswheel bearing
bolted to the is part hub
wheel of the wheel
and fronthub
discassembly.
brake rotor assembly.-
- The wheel hub assembly is attached to the front wheel spindle by a front axle wheel hub retainer.
> Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > Front > Page 1928
Wheels: Description and OperationRear
TheThe
rearrear wheel
wheel bearingis and
assembly inner as
installed wheel bearing oil seal are pressed into the axle tube assembly.
follows:-
- The semi-floating axle shafts are held in the rear axle housing by the U-washer positioned in a slot on the axle sh
- The wheel and tire assembly is bolted to the axle shaft flange by the lug bolt and lug nut.
- Each rear wheel is bolted to rear hub assembly.
-
The rear disc brake rotor is mounted to lug bolts on the rear axle shaft hub flange. The wheel and tire assembly m
- The rear wheel bearing is pressed into the outer axle tube housing.
- The axle shaft is retained in the rear axle housing by the U-washer.
> Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Bends/Dents
Wheels: Service and RepairBends/Dents

STRAIGHTENING WHEELS, RIMS OR COMPONENTS
Do not heat wheels in an attempt to soften them for straightening to repair damage from striking curbs, etc. The s
> Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Bends/Dents > Page 1931
Wheels: Service and RepairHub Mounting Flange
Corrosion build-up can result in wheels sticking to the hub flange or front disc brake rotor flange after extensive serv
grease to lug nut seats or lug nut.
3. Install wheel on vehicle.
Wheels: Service and RepairLeaks
NOTE: Wheel services that use welding, heating or peening are not approved. An inner tube is not an acceptable servi
DESCRIPTION
Slow leaks may occur in cast aluminum wheels because of porous wheel castings. Perform the following procedu
PROCEDURE
1. Remove the tire and wheel assembly and inspect the wheel for structural damage. If none exists, go to Step 2. If th
for possible additional leaks. When leaks are marked, dismount the tire marking the valve location on the tire for
3. On the tire side of the wheel, thoroughly clean the leaking area with Professional Choke and Linkage Cleaner E8A
meeting Ford specification ESR-M14P10-A or use sandpaper of approximately 80-grit to remove all contaminati
4. Use a clean cloth to remove all cleaner or sanding dust.
NOTE: Do not use a torch containing oxyacetylene.
5. Heat the prepared area with Rotunda Heat Gun 107-R0300 or equivalent or propane torch until Aluminum Wheel
E7AZ-19544-A
6. Apply or heat
only enough equivalent
to meltmeeting Ford
the sealer, specification
then remove heatESA-M4G280-A flows. Apply
source. After servicing the allow
the leak, hot melt
thematerial
wheel toov
co
CAUTION: Use caution when mounting the tire so as not to damage the sealer.
7. Index and assemble tire and wheel. Inflate tire to the recommended pressure as indicated on the tire pressure decal
Wheels: Service and RepairMaintenance
Steel
CAUTION:
-
Do not use steel wool, abrasive-type cleaner or strong detergents containing high alkaline or caustic agents as dam
-
Automatic car wash tire brushes may damage aluminum and styled road wheel protective coatings. Before using
To clean wheels and wheel covers, use a mild soap and water solution and rinse thoroughly with clear water.
Rim bead seats (steel wheels only) should be cleaned with a wire brush or coarse steel wool to remove lubricants, old r
Aluminum
CAUTION:
Do not use steel wool, abrasive-type cleaner or strong detergents containing highly alkaline or caustic agents as damag
NOTE:
Automatic car wash tire brushes may damage aluminum and styled road wheel protective coatings. Before using such
Aluminum wheel rim bead seats should be cleaned with a non-abrasive cleaner to remove tire mounting lubricants and
During Tire Changes

WARNING:
-
AFTERMARKET AEROSOL TIRE SEALANTS ARE EXTREMELY FLAMMABLE. ALWAYS QUEST
-
ALLOYS OR METAL SURFACES WITH CRACKS ARE VERY DANGEROUS. THESE COMPONENT
-
MAKE SURE REPLACEMENTS ARE MADE WITH THE PROPER SIZES AND TYPES OF WHEELS. FAIL
NOTE:
-
Avoid the use of any lubricant which contains water or solvent that is injurious to rubber such as WD40. A comb
- If the tire is to be reinstalled on the same wheel, mark the tire and wheel so they can be reassembled in the same p
PROCEDURE
1. Check all metal surfaces. Watch particularly for the following items:
-
Cracks in the rim bead seat or dropwell radii areas. These are caused by deep rim tool marks, overloading and
-
Cracks in the wheel disc, between the stud holes or hand holes. These are caused by loose lug nuts, improper
2. Replace the parts as necessary.3. Thoroughly remove rust, dirt and other foreign materials from all surfaces. Hand
should be free of rubber deposits.
NOTE:
Avoid the use of any lubricant which contains water or solvent that is injurious to rubber such as WD40. A com
4. Lubricate the tire side of the rim base just prior to mounting tire.
CAUTION: 276 kPa (40 psi),

When mounting a tire on a wheel, do not inflate to more than then deflate tire to prevent damage or personalinj
5. Inflate tire to recommended air pressure.

During Tire Inspection
WARNING: EXCESSIVELY CORRODED OR CRACKED RIMS CAN BE DANGEROUS. DEFLATE TIRE

1. Check all metal surfaces thoroughly while making tire inspections, including areas on inboard side of wheel. Watc
- Excessive rust or corrosion build-up.
- Cracks in metal.
- Bent flanges, resulting from road obstructions.
- Loose, missing or damaged lug nuts.
- Bent or stripped lug bolts.
2. Remove damaged wheels.3. Mark damaged or hazardous areas with chalk so that part will be removed from servic
apply grease to lug nut seats.
5. Replace parts as required.6. Inflate tires only to recommended air pressures.7. Check the wheel lug nut torque and
Maintenance and Protection In Corrosive Environments
Wheels have a protective coating to resist corrosion. Care should be taken to avoid damaging the wheel or corrosion m
1. Clean the wheels frequently with steam or high-pressure water from a hose. Use of a mild detergent will speed up
good results. The following procedure is suggested.
Surface Preparation 1. Remove all the soil and oil from the wheel surface with either high-pressure steam or so
regular paint thinner, obtained in paint stores.
2. Remove any adherent soil or oxidation products by using a wire brush.3. Clean the surface again with solvent,
Wheels: Service and Repair
Bends/Dents
Hub Mounting Flange
Leaks
DESCRIPTION
PROCEDURE

E7AZ-19544-A or equivalent meeting Ford specification ESA-M4G280-A flows. Apply the hot melt material ov
6. Apply only enough heat to melt the sealer, then remove heat source. After servicing the leak, allow the wheel to co
Steel
CAUTION:
-
-
Aluminum
CAUTION:
NOTE:
During Tire Changes

WARNING:
-
-
-
NOTE:
-
PROCEDURE
-
-
NOTE:

protective measure is of particular importance with drop-center tubeless rims as the air in the tire is contained by


- Cracks in metal.
Replacement
Are bent.
Wheels must be replaced when they:-
- Are dented or heavily rusted.
- Have air leaks (aluminum wheels can, in most cases, be serviced using the procedure under Cleaning and Inspect
- Have elongated bolt holes.
-
Have excessive lateral or radial runout. Wheels with a lateral or radial runout greater than the recommended spec
- load capacity
- diameter
- width
- offset and mounting configuration
An wheel andwheel
improper bearing lifeaffect:-
may
- ground and tire clearance
- speedometer and odometer calibrations
Corrosion buildup can result in wheels sticking to the hub rotor flange after extensive service. To prevent this from r
Replacements
WARNING:
NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, SUCH AS WHEN CHANGING A TIRE. T

NOTE:
Extended use of other than conventional spare tires on a traction-Lok rear axle could result in a permanent reduction i
REMOVAL
1. Remove the wheel cover by inserting end of wheel lug wrench and prying against wheel rim flange. Loosen, but d
CAUTION: Do not use heat to loosen a frozen wheel because heat can shorten the life of the wheel and damage
2. Raise the vehicle until the tire clears the floor.
CAUTION: To prevent damage, never use differential carrier as a lift point.
3. Remove the lug nuts. Remove the wheel from the wheel hub.4. If corrosion has formed around the center pilot hol
INSTALLATION
1. Clean all dirt and corrosion from the wheel hub mounting surface and center pilot hole of the wheel. Apply a thin
Grease to the axle pilot flange to reduce corrosion.
2. Place the wheel on the hub. Install the locking wire hubcap pedestal (if used) and the lug nuts. Tighten them altern
against the wheel hub.
115-142 Nm (85-104 ft. lbs.).3. Lower the vehicle. Tighten the lug nuts to
Valves
Replacement wheels may need to have an air valve installed. The air valve must be fully seated in the hole in the wheel
> Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure
Article No.99-11-1
06/14/99
^
^
CONTENTS
> Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page
1943

GENERAL PROCEDURES
Diagnostic Theory

Diagnostic Process
1944

Glossary of Terms
1945

Dynamic Balance
1946



1947

1948

1949

1950

a.
c.
d.
1951

-
Vibrate Software(R)
1952

ChassisEAR
EngineEAR

1953

Tracing Powder
d.
1954

Diagnostic Process
1955

1956

1957

1958

2. Pre-Drive Check
important
^
^
^
^
5. Road Test
Note:
^
1959

speed-related.
^
^
^

^
1960

Steering Input Test
^
Brake Test
^
^
^
^

^ WARNING:
^ CAUTION:
1961

^
WARNING:
CAUTION:
Note:
^
^ Start the engine.
^ CAUTION:
1962

1. Static operation
^
2. While cranking
3. At idle
^
1.
1. Speed related
-
Idle vibration
- or shake. GO to SymptomChart - Idle Noise/Vibration.
-
1963

-

-
-
Airvaries
Noise Leak with
wind/vehicle
2. Acceleration
-
4. Braking.
^
^
^
5. Clutching
1964

6. Shifting
^
8. Cruising speeds
1.

1965

1966

1967

1968

1969

1970

1971

1972

1973

1974

1975

1976

1977

1978

1979

1980

1981

1982

1983

1984

1985

1986

1987

1988

1989

1990

1991

1992

1993

1994

1995

1996

1997

1998

1999

Pinpoint Tests
2000

2001

2002

2003

2004

2005

2006

2007

2008

2009

2010

2011

2012

2013

2014

2015

2016

2017

2018

2019

2020

2021

2022

2023

2024

2025

2026

2027

2028

2029

2030

1. Open the hood.
2. Note:
Note:
4.
3. CAUTION:
2031

3.
6.
7.
2032

^
2033

2034

2035

WARNING:
4. CAUTION:

WARNING:
WARNING:
Note:
1. WARNING:
2036

CAUTION:
6.
^

Wheel Bearing Check
1. WARNING:

2. Note :
2037

^
> Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 2038
Wheel Bearing: Specifications

Lubricate the rear wheel bearing with Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford spe
Use Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B between the
Wheel Bearing: Description and Operation
-
The front wheel bearings are pregreased, sealed and require no scheduled maintenance. The front wheel bearings
-
- The front wheel bearings are of a wheel hub unit design and are pregreased, sealed and require no scheduled main
-
The wheel bearings are preset and cannot be adjusted. If a wheel bearing replacement is required for any service,
- The wheel bearings cannot be disassembled from the wheel hub and cannot be serviced separately.
- No individual service seals, roller or races are available.
- 255-345 Nm (189-254 ft. lbs.)The front axle wheel hub retainer torque of restricts wheel hub.
Each front wheel is bolted to a wheel hub assembly. The wheel bearing is an integral part of the wheel hub assem
Wheel Bearing: Testing and Inspection
Front wheel bearings that need replacing may be indicated by a noise that occurs only when turning. To diagnose the
- If the vehicle makes noises on right turns, the left wheel bearing may need to be replaced.
- If the vehicle makes noises on the left turns, the right wheel bearing may need to be replaced.
255-345 Nm (189-254 ft. lbs.). 2. Spin the tire quickly by hand and make sure the tire turns smoothly without noise
of the wheel hub and wheel bearing assembly. There should be no perceptible end play. If there is perceptible end
Wheel Bearing: Adjustments
255-345 Nm (189-254 ft.lbs.) The front wheel bearings are pregreased sealed and require no scheduled maintenance. T
Wheel Bearing: Service and Repair
REMOVAL
1. Raise vehicle on hoist.2. Remove wheel and tire assembly.3. Remove front hub cap grease seal from wheel hub an
CAUTION: Do not let disc brake caliper hang by the front brake hose. Damage to front brake hose may result.
5. Remove disc brake caliper assembly and suspend with wire.6. Remove front disc brake rotor. If factory push-on n

8. Remove wheel hub assembly. If assembly cannot be removed by hand, use Front Hub Remover/Replacer T81P-11
INSTALLATION
255-345 Nm (189-254 ft. lbs.).
200 Nm (147 ft. lbs.).

115-142 Nm (85-104 ft. lbs.). 1. Install wheel hub.2. Install new front axle wheel hub retainer and tighten to 3. Insta
> Maintenance > Wheels and Tires > Wheel Cover > Component Information > Description and Operation > Base Wheel Covers
Wheel Cover: Description and OperationBase Wheel Covers

-
The base wheel covers are stainless steel with integral retainer clips. The cross spoke steel covers are full plastic
-
Both wheel cover latches engage an undercut in the wheel at the safety bead. Use care to line up the cover windo
- When installing these wheel covers, do not force or hammer on the face of the wheel cover. They can be installed
> Maintenance > Wheels and Tires > Wheel Cover > Component Information > Description and Operation > Base Wheel Covers > Page 2048
Wheel Cover: Description and OperationWire Wheel Covers
A pedestal
Optional cup(anti-theft)
locking is attachedwheel
to thecovers
wheel are
withavailable.-
flanged lug nuts.
- A special bolt reaches through the center of the wheel cover to a pierce nut on top of the pedestal cup.
- A center wheel cover applique snaps onto the wheel cover, hiding the head of the lock bolt.
- Use care when installing or removing.
- A key wrench is used to lock the wheel cover to the pedestal cup and to remove the wheel cover applique.
- A decal on the underside of the luggage compartment door next to the jacking instructions contains the lock bolt
-
To allow vehicle service in the event the key has been misplaced, a Rotunda Locking Wire Wheel cover Master K
- The key has a circular keyway that is attached to the female slot in the anti-theft lock bolt.
> Maintenance > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Cleaning
Wheel Cover: Service and RepairCleaning

CAUTION:
-
Do not use steel wool abrasive-type cleaner or strong detergents containing highly alkaline or caustic agents as da
-
To clean wheels, wheel covers and wheel cover appliques, use a mild soap and water solution and rinse thoroughly wit
> Maintenance > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Cleaning > Page 2051
Wheel Cover: Service and RepairHub Caps
Part 1 Of 2
Part 2 Of 2
Remove or install the anti-theft lock bolt as follows:1. Insert the key into the slot of the lock bolt.2. Apply pressure o
and cap when installing the wheel cover. When installing these wheel covers, do not force or hammer on the face
NOTE:
Both the base and bright wire wheel covers are full plastic wheel covers with integral plastic latches which retai
> Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications
Axle Nut: Specifications

Front Retaining Nut .............................................................................................................................................................
> Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence
Lug Nut Torque Patterns

> Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 2060
Wheel Fastener: SpecificationsWheel Tightening Torque

Lug Nuts ...........................................................................................................................................................................
Tighten lug nuts alternately to draw the wheel evenly against the wheel hub.
> Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 2061
Wheel Fastener: Description and Operation
NOTE:
- Aluminum wheels must use special bulge-type metric (M-12) lug nuts with enlarged chamfers or distortion of the
-
All vehicles use metric (M-12) lug nuts. Replacement lug nuts must be of the same type and thread size. All metr
ANTI-THEFT
The keywheels
Aluminum is attached to the wheel
on vehicles lug nut wrench,
are equipped stowedlug
with anti-theft with the(one
nuts spare
pertire.
wheel) that are installed during vehicle p
-
To allow vehicle service in the event the key has been misplaced, a Rotunda Master Service Tool Set 164-R3104
-
115-142Nm (85-104 ft. lbs.). The key has a circular keyway that is matched to the female slot in the anti-theft lu
> Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Fastener
Wheel Fastener: Service and RepairWheel Fastener
Anti-Theft
CAUTION:
-
Make sure the key is held square to the lug nut. If the key is on an angle, it may damage the key and the anti-thef
- DO NOT use a power impact wrench on the lug nut key.
115-142Remove or install the anti-theft lug nut as follows:1. Insert the key into the slot of the lug nut.2. Place the wh
Nm (85-104 ft. lbs.).
Regular
CAUTION
Failure to tighten lug nuts in a star pattern may result in high rotor runout, which will speed up the development of bra
- Install lug nuts using Rotunda Accutorq Lug Nut Sockets 164-R0303 or equivalent on a 1/2-inch drive impact wr
- 115-142 Nm (85-104 ft. lbs.).Tighten to
> Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Fastener > Page 2064
Wheel Fastener: Service and RepairWheel Stud
Front
REMOVAL
1. Raise vehicle on hoist.2. Remove wheel and tire assembly.3. Remove disc brake caliper and front disc brake rotor
INSTALLATION
1. Install lug bolt into wheel hub.2. Using a lug nut, seat wheel hub bolt into wheel hub.3. Install front disc brake roto
Rear
REMOVAL
1. If equipped, turn the air suspension service switch, located in the luggage compartment, OFF.
WARNING: IF EQUIPPED, THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUS
2. Raise and support the vehicle.3. Remove the wheel and tire assembly.4. Remove the rear disc brake caliper, rear d
> Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Fastener > Page 2065

5. Using C-Frame and Clamp Assembly 211-023 (T74P-3044-A1), press the wheel hub bolt from its seat and discard
INSTALLATION
CAUTION: Never use air tools to install wheel hub bolts. The serrations can be stripped from the stud.
1. Insert a new wheel hub bolt in the hole in the axle flange, making sure serrations are aligned with those made by th
> Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure
SAFETY RECALL00S13
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
Attachment

> Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jacking
Procedure > Page 2074

PLEASE NOTE
PROMPTLY CORRECT

LABOR ALLOWANCES
PARTS REQUIREMENTS


NOTE:

NOTE:
1.

1.


> Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle Jackin
SAFETY RECALL00S13
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
Attachment

> Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Jul > 00 > Recall -

PLEASE NOTE
PROMPTLY CORRECT

LABOR ALLOWANCES
PARTS REQUIREMENTS


NOTE:

NOTE:
1.

1.


> Maintenance > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 2093
CAUTION:
Hoist, Drive On
CAUTION:
Vehicle Lift Points
Jack, Floor
CAUTION:

-
CAUTION:
Hoist, Drive On
CAUTION:
Vehicle Lift Points
Jack, Floor
CAUTION:

-
> Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications
> Engine, Cooling and Exhaust > Engine > Compression Check > System Information > System Diagnosis > Compression Test

TEST RESULTS
> Engine, Cooling and Exhaust > Engine > Compression Check > System Information > System Diagnosis > Compression Test > Page 2104
Example Readings
> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications
Camshaft Bearing: Specifications

Bearing Inside Diameter (All): 27.012-26.987 mm (1.06346-1.062478 inches)
Camshaft Bearing Cap to Cylinder Head: 8-12 Nm (71-106 Inch Lbs.)
> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications
Camshaft Gear/Sprocket: Specifications

Camshaft Sprocket Bolt ...................................................................................................................................................
> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications > Page 2112
Camshaft Gear/Sprocket: Testing and Inspection
Inspect the camshaft sprocket for warping or abnormal wear. Inspect the camshaft sprocket teeth for wear, deformation
> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications > Page 2113
Camshaft Gear/Sprocket: Service and Repair
SPECIAL TOOLS REQUIRED
REMOVAL
1. Remove camshaft timing chains and timing chain tensioners.2. Remove crankshaft sprockets from crankshaft.3. R
NOTE:
Cam Positioning Tool Adapters 303-413 and Cam Positioning Tool 303-380 must be installed on camshafts to pr
4. Inspect crankshaft sprockets and camshaft sprockets for wear or damage and replace as required.
CAUTION: Do not rotate crankshaft and/or camshafts or possible damage to engine may occur.
INSTALLATION
1. Position camshaft sprocket spacers and camshaft sprockets on camshafts.
NOTE:
Cam Positioning Adapters 303-413 and Cam Positioning Tool 303-380 must be installed on camshafts to prevent
2. Install washers and camshaft sprocket retaining bolts. Do not tighten at this time.
3. Install crankshaft sprockets onto crankshaft. Refer to the illustration for proper crankshaft sprocket installation.
NOTE: Crankshaft sprockets are identical. They may only be installed one way.
4. Install camshaft timing chains and timing chain tensioners.

> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications
Camshaft: Specifications
Lobe Lift
Intake ..........................................................................................................................................................................
Right Hand ...........................................................................................................................................................

Theoretical Valve Lift @ Zero Lash
Intake ..........................................................................................................................................................................
End Play ....................................................................................................................................................... 0.025-0.188
Service Limit ..............................................................................................................................................................
Journal to Bearing Clearance ....................................................................................................................... 0.025-0.076
Service Limit ..............................................................................................................................................................
Journal Diameter (All) ............................................................................................................................... 26.962-26.93
> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2117
Camshaft: Description and Operation

The camshafts are individually chain-driven with an automatic hydraulic timing chain tensioner on each timing chain.
> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Journal
Camshaft: Testing and InspectionJournal
Diameter
Measure the journal diameters in the X and Y directions at points A and B as shown.
Replace the camshaft if not within specification.
Journal Oil Clearance
1. Remove all foreign material and oil from the camshaft journals and cylinder head bearing surfaces.2. Set the cams
0.025-0.076 mm (0.0010-0.0029 inch). 0.121 mm (0.0048 inch).The standard camshaft oil clearance should be
> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Journal > Page 2120
Camshaft: Testing and InspectionLobe
Cam Lobe Inspection
Inspect the camshaft lobes for scoring and signs of abnormal wear. Lobe pitting (except in the general area of the lobe t
Lobe Lift
IN-VEHICLE INSPECTION
Check the lift of each lobe in consecutive order and make a note of the readings.
1. Remove valve covers.2. Remove rocker arms.3. Make sure valve tappet is seated. Install Dial Indicator with Brack
equivalent of indicator is on top of valve tappet and on the same plane as valve tappet.
4. Remove spark plugs.5. Connect an auxiliary starter switch in starting circuit. Crank engine with ignition switch in
is on base circle of camshaft lobe. At this point, the valve tappet will be in its lowest position. If checking during
6. Zero the dial indicator. Continue to rotate crankshaft slowly until valve tappet is in fully-raised position (highest in
NOTE:
If lift on any lobe is below specified service limits, camshaft and valve tappet operating on worn lobes must be re
8. To check accuracy of original indicator reading, continue to rotate crankshaft until indicator reads zero.9. Remove
10. Install rocker arms.
CAUTION:
After installing rocker arms, do not rotate crankshaft until valve tappets have had sufficient time to bleed down. O
11. Install valve covers.12. Install spark plugs.
CAMSHAFT REMOVED

1. Measure the distance between major (A-A) and minor (B-B) diameters of each cam lobe and make a note of the re
readings is lobe lift.
2. If lift on any lobe is below specified service limits, camshaft and valve tappets must be replaced,
Camshaft: Testing and InspectionCleaning and Inspection

CLEANING
Clean the camshaft in solvent and wipe it dry.
Remove light scuffs, scores or nicks from the camshaft machined surfaces with a smooth oil stone.
INSPECTION
NOTE:
0.5 mm (0.020 inch) 0.5 mm (0.020 inch),
If camshaft journals are excessively worn or scored, replace the camshaft. The cylinder head bearing journals can be
Check camshaft bores for size, taper, roundness, alignment and finish. If any of these exceed the limits given in Spec
Camshaft: Testing and InspectionEnd Play

1. Push camshaft toward rear of engine. Install Dial Indicator with Bracketry 100-002 or equivalent so indicator poin
CAUTION: Prying against the camshaft sprocket with the valve train load on the camshaft sprocket can break o
NOTE: Dial indicator may also be installed on rear of engine with indicator point placed on flat area of camshaf
2. Zero the dial indicator. Pull camshaft forward and release it. Compare dial indicator reading with specifications. If
binding or foreign material in camshaft thrust bearing. If end play is excessive, check for worn camshaft thrust pl
3. Remove dial indicator.
Camshaft: Testing and InspectionRunout
Inspect the camshaft runout by setting the No. 1 and No.4 journals on V-blocks and using Dial Indicator with Bracketry
0.05 mm (0.002 inch).Maximum runout of the camshaft is

> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Removal
Camshaft: Service and RepairRemoval

REMOVAL
1. Disconnect battery ground cable. 2. Relieve fuel system pressure and disconnect fuel lines.3. Remove air cleaner o
10. Disconnect positive battery cable at power distribution box.11. Remove retaining bolt from positive battery cable
from valve cover studs. Position out of way.
13. Disconnect fuel vapor hose from positive crankcase ventilation valve (PCV valve) and remove positive crankcase!
cover.
14. Disconnect fuel charging wiring at 42-pin connector and eight pin transmission harness connector at power brake
way.
15. Disconnect crankshaft position sensor, A/C clutch connectors.16. Raise vehicle on hoist.17. Remove bolts retainin
NOTE: The front lower bolt on the power steering pump will not come all the way out.
18. Install
20. Wire theCrankshaft
power steering
Damperpump
Remover
out of303-009
the way.19.
on crankshaft
Remove crankshaft
pulley andpulley
pull crankshaft
bolt and crankshaft
pulley from
pulley
crankshaft.21.
retaining w
> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Removal > Page 2127

26. Remove four bolts and seven stud bolts retaining LH valve cover to cylinder head and remove valve cover.27. Rem
engine front cover.
28. Remove timing chains.
29. Rotate crankshaft counterclockwise 45 degrees.
NOTE: This ensures that all pistons are below the top of the cylinder block deck face.
CAUTION: Crankshaft must be in this position prior to rotating camshafts or damage to pistons and/or valve tra
30. Install Valve Spring Compressor 303-381 under camshaft and on top of valve spring retainer.

31. Compress valve spring far enough to remove rocker arm.
NOTE:
Valve Spring Spacer 303-382 must be installed between valve spring coils. Camshaft must be at base circle befor
32. Repeat Steps 38 and 39 until all rocker arms are removed.
33. Remove 14 bolts retaining camshaft bearing caps to cylinder head.34. Tap upward on camshaft bearing caps at po

35. Remove camshaft straight upward to avoid bearing damage.36. Steps 35 through 40 will remove only one camsha
camshaft.
Camshaft: Service and RepairInstallation

INSTALLATION
1. Clean and inspect valve cover, engine front cover and cylinder head sealing surfaces.2. Position camshaft on cylin
NOTE: Each camshaft front bearing cap, and rear bearing cap is tightened individually.
8-12 Nm (71- 106 inch lbs.).

8-12 Nm (71-106 inch lbs.).4. Tighten camshaft bearing cap retaining bolts in sequence to 5. Loosen 14 camshaft be
NOTE: Camshaft should turn freely with a slight drag.
7. Check camshaft end play using Dial Indicator with Bracketry Tool-4201-C or equivalent.8. If necessary, install Ca
110-130 Nm (82-95 ft. lbs.).camshaft sprocket. Install bolt and washer and tighten to
9. Install Valve Spring Compressor 303-381 under camshaft and on top of valve spring retainer. Install valve tappet.
NOTE:
Valve Spring Spacer 303-382 must be installed between valve spring coils and the camshaft must be at base circl
10. Compress valve spring far enough to install rocker arm.
11. Repeat Steps 8 through 10 until all rocker arms are installed. Remove Valve Spring Spacer 303-382 from valve sp
NOTE:
Steps 2 through 10 will install only one camshaft. If both camshafts are being serviced, repeat Steps 2 through 10
12. Rotate crankshaft clockwise 45 degrees.
CAUTION: Crankshaft must only be rotated in the clockwise direction and only as far as top dead center (TDC

NOTE: This will position crankshaft at top dead center (TDC).
13. Install timing chain.
CAUTION: Timing chain procedures must be followed exactly or damage to valves and/or pistons will result.
14. Inspect and replace crankshaft front seal and (three piece) engine front cover gaskets as necessary.
NOTE:
Remove all traces of dirt, oil or previously applied sealant. Clean all sealing surfaces with Metal Surface Cleaner
15. Apply an 8-12 mm (0.32-0.47 inch) bead of Silicone Gasket and Sealant F6AZ- 19562-AA or equivalent in locatio
16. Install engine front cover on cylinder block.
CAUTION: Engine front cover must be rolled into place, do not slide engine front cover on oil pan gasket or en

20-30 Nm (15-22 ft. lbs.).17. Install stud bolts and bolts retaining engine front cover to engine. Tighten in sequence s
NOTE: Engine front cover must be installed and retaining bolts and stud bolts tightened to specification within f
18. Apply Silicone Gasket and Sealant F6AZ-19562-AA or equivalent WSE-M4G320-A6 to both places where the en
head.
NOTE:
19. Position and, using Silicone Gasket and Sealant F6AZ-19562-AA or equivalent, secure gaskets into valve covers a
cylinder heads.
8-12 Nm (71-106 inch lbs.).20. Install bolts and stud bolts into RH valve cover. Tighten all bolts to
NOTE: Valve covers must be installed and tightened within five minutes of applying sealant.

8-12 Nm (71- 106 inch lbs.).
21. Install bolts and stud bolts into LH valve cover. Tighten all bolts to 22. Raise vehicle on hoist.23. Connect fuel cha
20 Nm (15 ft. lbs.). 60 degrees.a. Tighten to b. Tighten an additional
20-30 Nm (15-22 ft. lbs.).27. Position power steering pump on engine and install four retaining bolts. Tighten to

28. Lower vehicle.29. Position fuel charging wiring on valve cover studs. Connect fuel charging wiring to the A/C clu
20-30 Nm (15-22 ft. lbs.).
30. Connect 42-pin engine harness connector and eight pin transmission harness connector at power brake booster.31.

43. Start engine and check for leaks. Check and add Super Premium SAE 5W30 Motor Oil XO-5W30-QSP as needed
> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Hydraulic Valve Tappets <--> [Lifter / Lash Adjuster, Valve] > Component Information > Specifications
Hydraulic Valve Tappets: Specifications

Diameter (Std) ............................................................................................................................................. 16.000-15.9

> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Hydraulic Valve Tappets <--> [Lifter / Lash Adjuster, Valve] > Component Information > Testing and Inspect
Overview
Hydraulic Valve Tappets: Initial Inspection and Diagnostic Overview

CAUTION:
If any part of the valve tappet assembly needs replacing, replace the entire valve tappet. Internal tolerances for the valv
Keep valve tappets in proper sequence so that they can be installed in their original position. Inspect and test each valve
CLEANING
Thoroughly clean all the parts in clean solvent and wipe them with a clean, lint-free cloth.
INSPECTION
Inspect the parts and discard the entire valve tappet if any part shows pitting, scoring or excessive wear. Replace the
Assemble the valve tappet and check for freeness of operation by pressing down on the plunger. The valve tappets ca
VALVE, BALL TIP-TAPPET WEAR
The valve tappet tip is ball-shaped with an oil hole in the top. Light radial scuffing is acceptable. Replace if medium-
Overview > Page 2141
Hydraulic Valve Tappets: Component Tests and General Diagnostics
Leakdown Test
1. Place valve tappet in tester with plunger facing upward. Pour hydraulic tester fluid into cup to a level that will cov
purchased from manufacturer of tester. Using kerosene or any other fluid will not provide an accurate test.
NOTE: Do not mix parts from different valve tappets. Parts are select-fitted and not interchangeable.
2. Place a 7.94 mm (0.312-inch) steel ball provided with tester in plunger cap.
NOTE: Valve tappets cannot be checked with engine oil in them. Only testing fluid can be used.
3. Adjust length of ram so that pointer is 1.59 mm (0.062 inch) below starting mark when ram contracts valve tappet
pointer passes Start Timing mark.
Use center mark on pointer scale as Stop Ramming point instead of original Stop Ramming mark at top of scale.
4. Work valve tappet plunger up and down until valve tappet fills with fluid and all traces of air bubbles have disappe
marks of tester.
6. A satisfactory valve tappet must have a leakdown rate (time in seconds) within minimum and maximum limits fou
because oil contained in new valve tappets is test fluid.
8. Remove fluid from cup and bleed fluid from valve tappet by working plunger up and down. This step will aid in d
when checking valve clearance.
Noise
Hydraulic valve tappet noise may be caused by any of the following:- excessive collapsed valve tappet gap.- sticking v
Excessive collapsed valve tappet gap may be caused by a worn valve tappet, roller valve tappets or valve tip. With valv
A sticking valve tappet plunger may be caused by dirt, chips or varnish inside the valve tappet. Correct the sticking by
Air bubbles in the lubrication system will prevent the valve tappet from supporting the valve spring load and may be ca
If the leak-down time is below the specified time for used valve tappets, noisy operation may result. If no other cause f
Assembled valve tappets can be tested with a hydraulic tappet leakdown tester to check the leak-down rate. The leak-do
Hydraulic Valve Tappets: Service and Repair

REMOVAL
1. Remove rocker arms.2. Remove valve tappets from cylinder heads.3. Clean and inspect valve tappets.
INSTALLATION
1. Apply clean Super Premium SAE 5W30 Motor Oil XO-5W30-QSP meeting Ford specification WSS-M2C153-G
roller contact surfaces and valve tappets and cylinder head valve tappet bore.
2. Install valve tappets into cylinder heads.
NOTE: Valve tappets must have no more than 1.0 mm (0.039 inch) of plunger travel prior to installation.
3. Install rocker arms.

> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications
Rocker Arm Assembly: Specifications

Ratio .................................................................................................................................................................................
> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 2146
Rocker Arm Assembly: Testing and Inspection

CLEANING
Clean all parts thoroughly using solvent. Make sure all oil passages are open.
INSPECTION
Inspect the pad at the valve end of the rocker arm for indications of scuffing or abnormal wear. If the pad is grooved,
Inspect rocker arm roller for abnormal wear. Rotate rocker arm roller to check for bearing wear. If any wear or dama
> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 2147
Rocker Arm Assembly: Service and Repair

REMOVAL
1. Remove valve covers.2. Position piston of cylinder being serviced at the bottom of its stroke and camshaft lobe at
3. Install Valve Spring Spacer 303-382 between valve spring coils to prevent valve stem seal damage.
CAUTION: If Valve Spring Spacer 303-382 is not used, valve spring retainer will hit valve stem seal and dama
4. Install Valve Spring Compressor 303-381 under camshaft and on top of valve spring retainer.5. Compress valve s
INSTALLATION
1. Apply clean Super Premium SHE 5W30 Motor Oil X0-5W30-4SP meeting Ford specification WSS-M2C153-G to
roller contact surfaces and valve tappet.
2. Install Valve Spring Spacer 303-382 between valve spring coils.3. Compress valve spring using Valve Spring Com
NOTE: Piston must be at the bottom of its stroke and camshaft at base circle.
4. Remove valve spring compressor and spacer.5. Repeat Steps 1 through 4 until all rocker arms are installed.6. Insta
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications
Connecting Rod Bearing: Specifications

Desired Clearance to Crankshaft .................................................................................................................. 0.027-0.06

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Over
Connecting Rod Bearing: Initial Inspection and Diagnostic Overview

CLEANING
Identify reusable bearings so they can be installed in their original locations.
CAUTION: Do not scrape gum or varnish deposits from the bearing shells or damage to bearings may occur.
Clean the bearing inserts and caps thoroughly in solvent and dry them with compressed air.
INSPECTION
Inspect each bearing carefully. Replace bearings with a scored, chipped or worn surface. Typical examples of unsatis
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Over
Connecting Rod Bearing: Component Tests and General Diagnostics

PLASTIGAGE(R) METHOD
1. Clean crankshaft journals. Inspect journals and thrust faces for nicks, burrs or roughness that would cause prematu
2. If fitting crankshaft main bearing in vehicle, position a jack under counterweight adjoining crankshaft main bearin
Support crankshaft with jack so its weight will not compress Plastigage(R) and provide an erroneous reading.
CAUTION: Do not position jack under crankshaft pulley. Crankshaft post damage will result.
3. Place a piece of Plastigage(R) 303-D031 or equivalent on bearing surface across full width of bearing cup and abo
center.
4. Install cap and tighten bolts to specification. Do not turn crankshaft while Plastigage(R) is in place.5. Remove cap
maximum clearance. Difference between reading its taper of journals.
6. If crankshaft journals are damaged or if bearing clearance exceeds the specified limits, refinish crank journal to 0.2
and use the appropriate undersize bearing.
7. After bearing has been fitted and cleaned, apply a light coat of clean engine oil meeting Ford specification WSS-M
bearings. Install bearing cap. Tighten cap bolts to specification.
8. Repeat procedure for remaining bearings that require replacement.
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Testing and Inspection > Page 2155
Connecting Rod Bearing: Service and Repair

REMOVAL
1. Remove oil pan and oil pump screen cover and tube.
2. Turn crankshaft until connecting rod bearing to be removed is accessible. If more than one connecting rod bearing
connecting rod caps, connecting rods and connecting rod bearings for cylinder position.
NOTE:
-
Connecting rod caps, connecting rods and connecting rod bearings should be numbered to make sure they
3. Remove the connecting rod cap, lower connecting rod bearing and upper connecting rod bearing. Keep cap and co
Use care to prevent damage to the bearing, cylinder bore and crankshaft surfaces.
4. Connecting rod bolts are retained in the connecting rod cap hole with a light press fit. The connecting rod bolts ha
twice and must be discarded. Use a hammer and punch to drive connecting rod bolts from connecting rod can.
CAUTION:
- Care should be taken not to damage the fractured rod and cap joint face surfaces or possible damage to eng
- Do not re-use the connecting rod bolts. They have been torqued to yield at least twice and must be discard
5. Inspect the connecting rods, connecting rod caps and crankshaft.
INSTALLATION
CAUTION:
Be sure not to scratch cylinder wall or crankshaft journal with connecting rod. Pull piston down until connecting
4. Install lower connecting rod bearings in the connecting rod caps. Align retaining tang of connecting rod bearing w
NOTE:
Due to the use of a cracked connecting rod joint face surface, the connecting rod cap must be properly aligned to
5. Alternately tighten connecting rod cap bolts in three steps:
20-25 Nm (15- 18 ft. lbs.).
40-45 Nm (30-33 ft. lbs.).
90-120
Afterdegrees. a. Tighten
all connecting rodtocapb.bolts
Tighten
are to c. Tighten
tightened an additionalrotate the crankshaft to make sure of smooth
to specification,
1. Clean crankshaft connecting rod journals with a clean cloth.2. Lubricate crankshaft and connecting rod bearing su
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Testing and Inspection > Page 2156

0.15-0.45 mm (0.006-0.01776. Check connecting rod side clearance using Dial Indicator with Bracketry 100-002 or
inch). 0.50 mm (0.020 inch), If side clearance is greater than maximum service limit of replace connecting rods
7. Install oil pump screen cover and tube and oil pan with new oil pan gasket.
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bolt
Connecting Rod: Specifications
Connecting Rod Cap Bolts Step 1 20-25 Nm (15-18 ft.lb)

Alternately tighten NEW connecting rod cap bolts in three
steps.
Step 2 40-45 Nm (30-33 ft.lb)
Step 3 Additional 90-120

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bolt > Page 2161
Connecting Rod: SpecificationsConnecting Rod, Engine

Piston Pin Bore Diameter .......................................................................................................................... 21.959-21.97

Twist ................................................................................................................................................ 0.050 per 25 mm
Side Clearance (Assembled to Crank)
Standard ..................................................................................................................................................... 0.015-0.4
Connecting Rod Bolt
Tighten
Tighten in 3tosteps:-
20-25 Nm (15-18 Ft. Lbs.)
- Tighten to 40-45 Nm (30-33 Ft. Lbs.)
- Tighten an additional 90-120 degrees.
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Connecting Rod Bending Clearance
Connecting Rod: Testing and InspectionConnecting Rod Bending Clearance
Check the connecting rods for bend or twist on a suitable alignment fixture. Follow the instructions of the fixture manu
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Connecting Rod Bending Clearance >
Connecting Rod: Testing and InspectionConnecting Rod Side Clearance
1. Install Dial Indicator with Bracketry 100-002 or equivalent so that the contact points rests against the connecting r
If side clearance is less than specification, remove connecting rod and cap. Inspect for scratches, burrs, nicks or d
Connecting Rod: Testing and InspectionInspection

CAUTION:
- Care should be taken not to damage the fractured rod and cap joint face surfaces or possible damage to eng
- Do not re-use the connecting rod bolts. They have been torqued to yield at least twice and must be discard
-
It is not necessary to ream or hone the piston pin bore in the connecting rod. Replace damaged connecting
0.007-0.013 mm (0.0003-0.0005 inch)

Inspect the connecting rods for signs of fractures and the bearing bores for out-of-round and taper. If the bore exc
TheAconnecting
shiny surface
rodsonand
either pin parts
related boss inside
shouldof
bethe piston usually
carefully indicates
inspected that a so
and checked connecting rod istobent.
they conform specification
- Abnormal connecting rod bearing wear can be caused by a bent connecting rod, worn or damaged crankpin or
-
Twisted connecting rods can create an identifiable piston skirt wear pattern, but badly twisted connecting rods
- Twisted connecting rods may also cause excessive oil consumption.
Connecting Rod: Testing and InspectionPiston Pin Clearance
1. Use a micrometer to inspect the piston pin diameter in the X and Y directions at points A, B. C and D as shown.
2. Measure connecting rod pin end inner diameter.3. Calculate piston pin press to connecting rod by subtracting pin d
0.015-0.040 mm (0.0006-0.0016 inch).is
4. If the piston pin bore in the connecting rod is larger than specification, install a 0.025 mm (0.001 inch) oversize pi
0.007-0.013 mm (0.0003-0.0005 inch)piston pin to the piston pin bore by reaming or honing the piston to provid
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Page 2167
Connecting Rod: Service and Repair
Remove the bearings from the connecting rod and cap. Identify each connecting rod bearing location if they are t
CAUTION: Do not use a caustic cleaning solution. Damage to connecting rods may occur.
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Testing and Inspection
Crankshaft Gear/Sprocket: Testing and Inspection
CAUTION: Handle crankshaft sprocket with care to avoid possible damage to the finished surfaces.
Inspect crankshaft sprocket for nicks, burrs or roughness that would cause premature wear. If crankshaft sprocket is w
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Testing and Inspection > Page 2171
Crankshaft Gear/Sprocket: Service and Repair

REMOVAL
NOTE:
INSTALLATION
NOTE:
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications
Crankshaft Main Bearing: Specifications

Desired Clearance to Crankshaft .................................................................................................................. 0.027-0.06
Crankshaft Main Bearing Cap Adjusting Screws ............................................................................................................
First step ....................................................................................................................................................................

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Testing and Inspection > Crankshaft Main and Connecting Rod
Crankshaft Main Bearing: Testing and InspectionCrankshaft Main and Connecting Rod Bearings
CLEANING
Identify reusable bearings so they can be installed in their original locations.
CAUTION: Do not scrape gum or varnish deposits from the bearing shells or damage to bearings may occur.
Clean the bearing inserts and caps thoroughly in solvent and dry them with compressed air.
INSPECTION
Inspect each bearing carefully. Replace bearings with a scored, chipped or worn surface. Typical examples of unsatis
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Testing and Inspection > Crankshaft Main and Connecting Rod
Crankshaft Main Bearing: Testing and InspectionFitting

PLASTIGAGE(R) METHOD
1. Clean crankshaft journals. Inspect journals and thrust faces for nicks, burrs or roughness that would cause prematu
2. If fitting crankshaft main bearing in vehicle, position a jack under counterweight adjoining crankshaft main bearin
Support crankshaft with jack so its weight will not compress Plastigage(R) and provide an erroneous reading.
CAUTION: Do not position jack under crankshaft pulley. Crankshaft post damage will result.
3. Place a piece of Plastigage(R) 303-D031 or equivalent on bearing surface across full width of bearing cup and abo
center.
4. Install cap and tighten bolts to specification. Do not turn crankshaft while Plastigage(R) is in place.5. Remove cap
maximum clearance. Difference between reading its taper of journals.
6. If crankshaft journals are damaged or if bearing clearance exceeds the specified limits, refinish crank journal to 0.2
and use the appropriate undersize bearing.
7. After bearing has been fitted and cleaned, apply a light coat of clean engine oil meeting Ford specification WSS-M
bearings. Install bearing cap. Tighten cap bolts to specification.
8. Repeat procedure for remaining bearings that require replacement.
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Testing and Inspection > Page 2178
Crankshaft Main Bearing: Service and Repair

REMOVAL
1. Remove engine from vehicle.2. Remove crankshaft.3. Clean and inspect cylinder block, crankshaft, crankshaft ma
INSTALLATION
1. Replace crankshaft main bearing, crankshaft thrust main bearing and crankshaft thrust washer. Fit crankshaft main
main bearing into main bearing caps.
3. Install crankshaft.4. Install engine into vehicle.

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications
Crankshaft: Specifications
Main Bearing Journal Dia. ......................................................................................................................... 67.483-67.50

Diameter .............................................................................................................................................. 52.988-53.00
Crankshaft Free End Play ............................................................................................................................ 0.130-0.301

Rear Face of Block ............................................................................................................................................... 0.0
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 2182
Crankshaft: Description and Operation
Theiscrankshaft:-
supported on the bottom of the cylinder block by five steel-backed, over-plated aluminum crankshaft main
- connects with the camshafts by two sprockets and two timing chains.
The rear crankshaft thrust main bearing limits crankshaft end play and absorbs thrust loads applied to the cranksh
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Testing and Inspection > Cleaning and Inspection
Crankshaft: Testing and InspectionCleaning and Inspection

CLEANING
CAUTION: Handle the crankshaft carefully to avoid damage to the finished surfaces.
Clean the crankshaft with solvent and then blow out all oil passages with compressed air.
INSPECTION
Inspect the main and connecting rod journals for cracks, scratches, grooves, scores or rough finish. Inspect the crank
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Testing and Inspection > Cleaning and Inspection > Page 2185
Crankshaft: Testing and InspectionEnd Play
1. Install crankshaft into cylinder block.2. Install Dial Indicator with Bracketry 100-002 or equivalent so contact poin
crankshaft axis.
3. Zero the dial indicator. Push crankshaft forward and note reading on dial.4. If the end play exceeds the wear limit
to the thrust face before installing the new crankshaft thrust main bearing. If the end play is less than the minimum
Crankshaft: Testing and InspectionJournal

Inspect the main journal and connecting rod journal diameters. Measure the diameter of each journal at two different po
67.483-67.503 mm (2.6568-2.6575 inch).The standard main journal diameter is
52.988-53.003 mm (2.0859-2.0867 inch).The standard connecting rod journal diameter is
If a main journal or connecting rod journal diameter is less than specifications, grind the journal to match an undersize
Crankshaft: Testing and InspectionRunout

Set the crankshaft on V-blocks and use Dial Indicator with Bracketry 100-002 or equivalent to measure the cranksha
0.03 mm (0.0012 inch).Maximum crankshaft runout is If the crankshaft runout exceeds specification, replace the cr
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal
Crankshaft: Service and RepairRemoval
See: Tools and Equipment

1. Remove ignition wires.
NOTE: This procedure will remove and install the crankshaft with the engine removed from the vehicle.
2. Remove six flywheel retaining bolts and remove flywheel from crankshaft.3. Remove accessory drive belt.4. Rem
6. Remove oil bypass filter.

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal > Page 2190

7. Remove RH and LH valve covers from cylinder heads.8. Remove crankshaft pulley.

9. Remove oil pan and oil pan gasket.

10. Remove engine front cover.
11. Position crankshaft 15 before top dead center (TDC).
NOTE: This will position all pistons below top of cylinder block deck face.
12. Remove timing chains.


13. Remove oil pump screen cover and tube and oil pump.14. Remove crankshaft oil slinger and crankshaft rear oil se
Hammer.

15. Remove crankshaft rear oil seal retainer.16. Turn crankshaft until connecting rod cap to be removed is accessible.
bearings for cylinder position.
17. Remove the connecting rod cap and lower and upper connecting rod bearings. Keep cap and connecting rod bearin
damage to the bearing, cylinder bore and crankshaft surfaces.
NOTE: rod bolts are retained in the bolt hole with a light press fit. The connecting rod bolts have been torqued
18. Connecting
Connecting
be discarded.rods,
Useconnecting rod punch
a hammer and caps and connecting
to drive rod bearings
connecting should
rod bolts from be numberedrod
connecting to can.
make sure they are ass
CAUTION: Care should be taken not to damage the fractured rod and cap joint face surfaces or engine damage

19. Remove horizontal main cap side bolts from cylinder block.20. Loosen crankshaft main bearing cap adjusting scre
bearing and crankshaft thrust main bearing together.
NOTE:
The location of the main bearing caps and the crankshaft main bearings should be identified. When the engine is
23. Remove crankshaft.
CAUTION: When removing the crankshaft, use care not to damage any of the bearing surfaces on the cranksha
24. If required, replace crankshaft main bearings,crankshaft thrust main bearing and crankshaft thrust washer.
Crankshaft: Service and RepairInstallation

1. Lubricate with clean engine Super Premium SAE 5W30 Motor Oil XO-5W30-QSP Ford specification WSS-M2C
main bearings into cylinder block. Install crankshaft main bearings and crankshaft thrust main bearing into main
NOTE: All sealing surfaces must be clean and free of chips, dirt, paint and foreign material. Also make sure oil
2. Install crankshaft into cylinder block.
CAUTION: Use care when installing crankshaft or damage to the bearing corners or surfaces may occur.
3. Push crankshaft rearward. Lubricate and install upper crankshaft thrust washer by rolling the crankshaft thrust was
rear side of No. 5 bulkhead and thrust surface of crankshaft. Make sure coated side of crankshaft thrust washer w

4. Install main bearing caps. Tap main bearing caps with a brass hammer to seat caps properly.
NOTE: Crankshaft main bearing cap adjusting screws must be bottomed on main bearing caps prior to installati
5. Push crankshaft forward using a pry bar or similar tool so that crankshaft thrust face is flush to number five bulkhe
6. With crankshaft pushed forward, install prybars or similar tools to push both RH and LH front edges of No. 5 main
position the lower crankshaft thrust main bearing rear face properly against the thrust face of the crankshaft.
NOTE: No. 5 main bearing cap must be seated until the main bearing cap bolts are fully tightened as described b
7. Tighten new main bearing cap bolts in two steps as follows:
37-43 Nm (28-31 ft. lbs.).
a. Tighten bolts in sequence to b. Rotate bolts in sequence 85-95 degrees.

CAUTION: Main bearing bolts must be replaced with new bolts. They are torque-to-yield design and cannot be
9-11 Nm (80-97 inch lbs.).

19-23 Nm (14-17 ft. lbs.).8. Tighten crankshaft main bearing cap adjusting screws in sequence to 9. Tighten main b
10. Check crankshaft end play in both directions as shown.
NOTE: Pry against number two main bearing cap.
11. Apply a 2.0 mm (0.08 inch) continuous bead of Sealant 509 F3AZ-19554-AA to cylinder block as shown.
- NOTE: Crankshaft rear oil seal retainer must be installed and bolts tightened to specification within five
Rear Oil Seal Retainer Tightening Sequence
8-12 Nm (71-106 inch lbs.).12. Install crankshaft rear oil seal retainer to cylinder block and tighten six bolts in sequen

13. Using Rear Seal Replacer Adapter 303-518, Rear Main Seal Replacer and Rear Slinger Replacer, install crankshaf
slinger.
14. Turn crankshaft until the crankshaft throw is at bottom of stroke. Install upper connecting rod bearing onto connec
rod bearing and crankshaft with clean Super Premium SAE 5W30 Motor Oil XO-5W30-QSP.
15. Install connecting rod cap and lower connecting rod bearing and alternately tighten new connecting rod cap bolts i
20-25 Nm (15-18 ft. lbs.).
40-45 Nm (30-33 ft. lbs.).
90-120a. Tighten to b. Tighten to c. Tighten an additional degrees. After installation, rotate crankshaft to make
CAUTION:
Be sure not to scratch cylinder wall or crankshaft journal with connecting rod. Pull piston down until connecting
NOTE:
16. Check connecting rod side clearance using Dial Indicator with Bracketry 100-002 or equivalent. Clearance should
inch). If side clearance is greater than maximum service limit of 0.50 mm (0.020 inch), replace connecting rods a

17. Install oil pump and oil pump screen cover and tube.
NOTE:
Install new O-ring on oil pump screen cover and tube then start all bolts on oil pump and oil pump screen cover a
18. Rotate crankshaft to position as shown.
CAUTION: Failure to position crankshaft as shown will cause damage to pistons and/or valve train components.

NOTE: With crankshaft in this position, no piston will be at top dead center (TDC).
19. Rotate crankshaft clockwise to 45 degrees. This will position crankshaft at top dead center (TDC) No. 1.
CAUTION: Crankshaft must only be rotated in the clockwise direction and only as far as top dead center (TDC) No. 1
20. Install timing chains.


20 Nm (14 ft. lbs.)21. Install oil pan with new oil pan gasket. Tighten bolts to and then an additional 60 degrees in no
applying sealer.
22. Replace crankshaft front seal in engine front cover.


23. Install engine front cover.
24. Install crankshaft pulley using Crankshaft Damper Replacer 303-102.
NOTE: Silicone Gasket and Sealant F6AZ-19562-AA must be applied to crankshaft keyway prior to installing c
25. Install crankshaft pulley bolt and crankshaft pulley retaining washer. Tighten in four steps:
90 Nm (66 ft. lbs.).
47-53 Nm (35-39 ft. lbs.).

a. Tighten to b. Loosen one full turn. c. Tighten to d. Tighten an additional 85-95 degrees.

8-12 Nm (71-106 inch lbs.).26. Install RH and LH valve covers. Tighten studs and bolts to
20-30 Nm (15-22 ft. lbs.).
20-30 Nm (15-22 ft. lbs.).
73-87 Nm (54-64 ft. lbs.).
27. Install new oil bypass filter.28. Install drive belt idler pulley, and ignition coil mounting brackets with ignition coi
Crankshaft: Service and RepairRefinishing
Dress minor imperfections such as scores, nicks or burrs with an oil stone. If the journals are severely marred or exce
If required, machine the journals to give the proper clearance with the next undersize bearing. If the journals will not
Always reproduce the same journal shoulder radius that existed originally. Too small a radius will result in fatigue fa
After refinishing the journals, chamfer the oil holes. Polish the journal with a No.500 grit polishing cloth and engine
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation
Engine Block Heater: Description and Operation
The optional block heater consists of an electrical heating element installed in one of the core plug openings in the cylin
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Engine Block Heater
Engine Block Heater: Service and RepairEngine Block Heater
REMOVAL
CAUTION:
1. Open hood and install protective fender covers.2. Disconnect battery ground cable.3. Position drain pan below rad
radiator to a corresponding level below block heater. Close radiator draincock.
WARNING: NEVER REMOVE THE PRESSURE RELIEF CAP UNDER ANY CONDITIONS WHILE
5. Disconnect block heater power cable from block heater.6. Loosen retaining screw and pry block heater from cylin
INSTALLATION
1. Clean the inside diameter of the cylinder block hole machined surface and hole entrance. Remove any burrs at the
to the O-ring.
1.6-1.8 Nm (15-16 inch lbs.).2. Apply a liberal coating of Premium Long Life Grease XG-1-K or equivalent to block
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Engine Block Heater > Page
2212

5. Connect block heater power cable to block heater.6. Install block heater power cable. Make sure power cable is ro
Coolant F6AZ-19544-AA (orange), or equivalent.
8. Connect battery ground cable.9. Start engine and check for leaks.
10. Check engine coolant level and fill as required.11. Remove fender covers and close hood.
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Engine Block Heater > Page 2213
Engine Block Heater: Service and RepairEngine Block Heater Cord

REMOVAL
1. Raise vehicle on hoist.2. Disconnect block heater power cable from block heater.3. Lower vehicle.4. Disconnect b
INSTALLATION
1. Follow removal procedure in reverse order.2. Make sure power cable is routed and secured away from rotating or
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug > Component Information > Service and Repair
Expansion/Freeze Plug: Service and Repair
To remove a large core plug, drill a 12.70 mm (0.50 inch) hole in the center of the plug and remove with an Impact S
Prior to installing a core plug, the plug bore should be inspected for any damage that would interfere with the proper
Oversize plugs are identified by the OS stamped in the flat located on the cup side of the plug.
Coat the plug and / or bore lightly with an oil-resistant (oil galley) Stud and Bearing Mount EOAZ- 19554-BA or equ
CUP-TYPE
Cup-type core plugs are installed with the flanged edge outward. The maximum diameter is located at the outer edge
CAUTION:
It is important to push or drive the plug into the machined bore by using a properly designed tool. Do not drive the pl
NOTE: If the core plug replacing tool has a depth seating surface, do not seat the tool against a non-machined (casti
When installed, the flanged trailing, edge must be below the chamfered edge of the bore to effectively seal the plugg
EXPANSION-TYPE
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug > Component Information > Service and Repair > Page 2217

Expansion-type core plugs are installed with the flange edge inward. The maximum diameter of this plug is located a
CAUTION:
It is imperative to push or drive the plug into the machined bore using a properly designed tool. Do not drive the plug
NOTE: If the core plug replacing tool has a depth seating surface, do not seat the tool against a non-machined (casti
When installed, the trailing (maximum) diameter must be below the chamfered edge of the bore to effectively seal th
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer - Crankshaft Pulley > Component Information > Specifications
Harmonic Balancer - Crankshaft Pulley: Specifications

Pulley to Crankshaft Bolt
Tighten
Tighten in 4tosteps:-
90 Nm (66 Ft. Lbs.)
- Loosen one full turn.
- Tighten to 47-53 Nm (35-39 Ft. Lbs.)
- Tighten an additional 90 degrees.
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer - Crankshaft Pulley > Component Information > Specifications > Page 2221
Harmonic Balancer - Crankshaft Pulley: Service and Repair

REMOVAL
1. Disconnect battery ground cable. 2. Release drive belt tensioner and remove drive belt.3. Raise vehicle on hoist.4.
5. Install Crankshaft Damper Remover 303-009 on crankshaft pulley and pull crankshaft pulley from crankshaft.6. U
INSTALLATION
1. Lubricate seal bore in engine front cover and seal lip with clean Super Premium SAE 5W30 Motor Oil X0-5W30-
WSS-M2C153-G.
2. Using Crankshaft Seal Replacer / Cover Aligner 303-335, install crankshaft front seal.
3. Using Crankshaft Damper Replacer 303-102, install crankshaft pulley.

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer - Crankshaft Pulley > Component Information > Specifications > Page 2222

4. Apply Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6
shown.
NOTE: Make sure key on crankshaft aligns with keyway of crankshaft pulley.
5. Install crankshaft pulley bolt and crankshaft pulley retaining washer.
90 Nm (66 ft. lbs.).
47-53 Nm (35-39 ft. lbs.).

85-95 degrees.Tighten the cylinder head in four steps:a. Tighten to b. Loosen one complete turn.c. Tighten to d.
6. Lower vehicle.7. Install drive belt.8. Connect battery ground cable.9. Start engine and check for leaks.
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications
Piston: Specifications
Piston Diameter (Without Coating)
Coded Red 1 .................................................................................................................................... 90.167-90.180 m

Piston Diameter (With Coating)
Coded Red 1 ........................................................................................................................................ 90.187-90.23
Piston-to-Bore Clearance ......................................................................................................................... 0.012-0.026 m
Compression (Top) .............................................................................................................................. 1.530-1.550

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Testing and Inspection > Cleaning and Inspection
Piston: Testing and InspectionCleaning and Inspection
Using a gasket scraper, remove deposits from the piston surfaces. Clean gum or varnish from the piston skirt, piston pin
Clean the ring grooves with Piston Ring Groove Cleaner 303-D033 or equivalent or a broken piston ring. Make sure oi
CAUTION: Do not use a caustic cleaning solution or a wire brush to clean pistons or possible damage may occur.
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Testing and Inspection > Cleaning and Inspection > Page 2228
Piston: Testing and InspectionInspection
Piston Outer Diameter
Measure the piston outer diameter using a micrometer. Measure piston skirt diameter at 90 degrees to piston pin center
Due to skirt coating, the piston size cannot be measured. Pistons are graded prior to skirt coating. Grade sizes with coat
- Grade 1: 90.187-90.212
- Grade 2: 90.200-90.225
- Grade 3: 90.213-90.238
Piston Pin Hole Diameter
Measure each piston pin hole diameter at the four points shown.
Replace piston that is not within specifications.

Use a micrometer to inspect the piston pin diameter in the X and Y directions at points A, B. C and D as shown.
Calculate piston pin to piston pin hole clearance by subtracting pin diameter from piston pin hole diameter.
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Testing and Inspection > Cleaning and Inspection > Page
2229

Replace piston pin that is not within specifications.
Piston Ring-to-Groove Clearance
NOTE: Always use a piston ring expanding tool to install rings on a piston.
1. Check side clearance of compression rings with Feeler Gauge 303-D027 or equivalent by inserting it between pist
Gauge should slide freely around entire piston ring circumference without binding.
NOTE: If lower lands have high steps, piston should be replaced.
0.040-0.090
Piston ring side mm (0.0016-0.0035
clearance inch)
should be as top ring:
follows:-
- 0.030-0.080 mm (0.0012-0.0031 inch)2nd ring:
0.15limit:-
Service mm max (0.006 inch max) top ring:
- 0.15 mm max (0.006 inch max)2nd ring:
2. If clearance is greater than service limit, replace piston ring. If clearance exceeds service limit after new piston rin
Piston-to-Cylinder Clearance
Special Tools Required
2230

Measure cylinder bore diameter in two directions, A and B, as shown.
Measure cylinder bore diameter in both directions at 12.70 mm (0.50 inch) below top of cylinder block deck.
Measure cylinder bore diameter in both directions at 12.70 mm (0.50 inch) above top of the piston with the piston at its
Measure cylinder bore diameter 32 mm (1.25984 inch) down from head deck at 90 degrees to the piston pin centerline.
The cylinder bore taper equals the difference between measurements A at top and B at bottom of cylinder bore.
The cylinder bore out of round equals the difference between measurements A and B when measured at the center of th
Pistons are graded prior to skirt coating. Exact clearance cannot be calculated. Clearance is determined based on bore p
If the taper, out-of-round and piston-to-cylinder bore clearance conditions of the cylinder bore are within specified limi
If installing new rings in a used cylinder that has not been refinished, remove the cylinder wall glaze using only spring-
1. Calculate the size of piston to be used by taking a cylinder bore check. Follow procedures described in Pistons-Fit
NOTE: After any refinishing operation, allow cylinder bore to cool. Make sure piston and bore are clean and dry
2. Select proper size piston to provide desired clearance. Measure piston diameter in-line with centerline of piston pi
axis.
3. Make sure piston and cylinder block are at room temperature, approximately 21 C (70 F).
Pistons-Fitting
The standard-size pistons are color-coded red, blue and yellow. Oversize pistons are shown in Specifications.
2231

Measure the cylinder bore and select the piston to verify the proper clearance. When the bore diameter is in the lower o
Procedures
Carefully inspect the pistons for fractures at the ring lands, skirts, oil ring slot corners, and pin bosses. Also inspect for
Spongy, eroded areas near the edge of the top of the piston are usually caused by detonation or preignition. A shiny sur
Replace pistons showing signs of fracture, etching or wear. Check the piston pin fit in the piston and connecting rod.
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Disassembly And Assembly
Piston: Service and RepairDisassembly And Assembly

DISASSEMBLY
1. Using Pin Remover / Replacer T 68P-6135-A, press piston pin through piston and connecting rod.2. Clean and ins
ASSEMBLY
1. Apply a light coat of clean Super Premium SAE 5W30 Motor Oil XO-5W30-QSP to all parts.2. Heat piston pin en
4. Start piston pin in piston and connecting rod. This may require a very light tap with a mallet. Using Pin Remover/R
piston pin through piston until piston pin is centered in piston. After assembly, make sure connecting rod swings
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Disassembly And Assembly > Page 2234
Piston: Service and RepairRemoval and Installation
Removal
1. Remove RH and LH cylinder heads.2. Remove and discard head gaskets.3. If cylinder heads are to be serviced.4. R
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Disassembly And Assembly > Page
2235

5. Remove oil pump screen cover and tube.6. Turn crankshaft until piston to be removed is at the high point of its tra
connecting rods and connecting rod caps for cylinder position.
NOTE:
- Pistons, connecting rods and connecting rod bearings should be numbered to make sure they are assemble
-
Before removing pistons, inspect the top of the cylinder bores. If necessary, remove the ridge and/or carbo
7. Remove the connecting rod cap and lower connecting rod bearing. Keep cap and lower connecting rod bearing tog
connecting rod assembly and upper connecting rod bearing through the top of the cylinder bore. Use care to prev
CAUTION: Care should be taken not to damage the fractured rod and cap joint face surfaces or possible damag
NOTE:
Connecting rod bolts are retained in the bolt hole with a light press fit. The connecting rod bolts have been torque
2236

8.Using a new connecting rod bolt, attach cap and lower connecting rod bearing to connecting rod and upper bearing
10. If required, disassemble piston from connecting rod.11. If required, replace piston rings.
Installation
1. Coat piston bores, pistons and rings, crankshaft journal and bearing surfaces with clean Super Premium SAE 5W3
Compressor 303-D032 or equivalent and Connecting Rod Guide 303-442.
CAUTION:
Be sure not to scratch cylinder wall or crankshaft journal with connecting rod. Push piston down until connecting
NOTE:
- Make sure piston ring gaps are rotated 30 degrees apart.
- Notch on piston to front of engine.
-
The connecting rod bolts have been torqued to yield at least twice and must be discarded. Use a hammer a
2237

3. Alternately tighten connecting rod cap bolts in three steps:
20-25 Nm (15-18 ft. lbs.).
40-45 Nm (30-33 ft. lbs.).
90-120 degrees.a. Tighten to b. Tighten to c. Rotate bolts an additional
After all connecting rod cap bolts are tightened to specification, rotate crankshaft to verify smooth operation.
NOTE:
2238

0.15-0.45 mm4. Check connecting rod side clearance using Dial Indicator with Bracketry 100-002 or equivalent. (cle
(0.006-0.0177 inch 0.50 mm (0.020 inch))). If side clearance is greater than maximum service limit of , replace c
5. Install oil pump screen cover and tube.
NOTE: Install new O-ring, then start all bolts on oil pump and oil pump screen cover and tube before tightening
2239

6. Install oil pan with new oil pan gasket.7. If cylinder heads are to be reused they must first be reconditioned/service
CAUTION: 8. Do not use sandpaper coarser than 600 grit.
NOTE:
Clean cylinder head gasket surface with a toluene-based paint thinner or gasket remover. If gasket material remai
9. Position new head gaskets on cylinder head.
NOTE: RH and LH head gaskets are NOT interchangeable.
2240

10. Rotate crankshaft to position as shown.
CAUTION: Failure to position crankshaft as shown will cause damage to pistons and/or valve train components
NOTE: With crankshaft in this position, no piston will be at top dead center (TDC).
11. Install cylinder heads.
CAUTION: Use care when positioning cylinder heads. Damage to cylinder block and/or cylinder heads may res
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications
Piston Pin: Specifications

Length ............................................................................................................................................................ 61.93-62.0

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Testing and Inspection > Diameter
Piston Pin: Testing and InspectionDiameter
Use a micrometer to inspect the piston pin diameter in the X and Y directions at points A, B. C and D as shown.
Replace piston pin that is not within specifications.

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Testing and Inspection > Diameter > Page 2246
Piston Pin: Testing and InspectionPiston Pin to Piston Clearance
1. Measure inner diameter of piston pin bore in piston. 2. Measure outer diameter of piston pin.3. Calculate piston pi
0.005-0.010 mm (0.0002-0.0004 inch).Standard piston pin to piston clearance is
4. If clearance exceeds specification, replace piston and piston pin.

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications
Piston Ring: Specifications

Ring Gap
Compression (Top) ...................................................................................................................................................

Oil Ring
Side Clearance ........................................................................................................................................................ 1

Ring Gap
Compression (Top) .................................................................................................................................. 0.13-0.26

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Testing and Inspection > End Gap
Piston Ring: Testing and InspectionEnd Gap

1. Measure end gap of all piston rings with Feeler Gauge 303-D027 or equivalent.
0.13-0.28
Piston mm
ring end gap(0.005-0.011
should be asinch) top ring:
follows:-
- 0.30-0.55 mm (0.012-0.022 inch)2nd ring:
- 0.25-0.77 mm (0.010-0.030 inch)oil ring rail:
NOTE:
These measurements are for measuring the ring gap in a 90.200 mm (3.551174 inch) bore. These values will incr
0.75 limit:-
Service mm max (0.030 inch max)top ring:
- 1.25 mm max (0.049 inch max)oil ring rail:
2. If end gap is greater than service limit, replace piston ring. If end gap exceeds service limit after new piston ring is
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Testing and Inspection > End Gap > Page 2252
Piston Ring: Testing and InspectionFitting
1. Select proper piston ring set for size of cylinder bore.2. Position piston ring in corresponding cylinder bore.
CAUTION: Use care when installing piston ring to avoid possible damage to piston ring or cylinder bore.
115 mm (4.5 inches)3. Insert piston ring into cylinder bore. Using a piston, push piston ring slightly beyond bottom
cylinder block deck face.
4. Verify position of piston ring in bore is square with cylinder wall and check piston ring end gap.
Piston Ring: Testing and InspectionInspection

Replace all piston rings that are scored, broken, chipped or cracked. Check the end gap and side clearance.
CAUTION: Piston rings should not be transferred from one piston to another, regardless of mileage. Piston ring failur
Piston Ring: Testing and InspectionRing to Groove Clearance
NOTE: Always use a piston ring expanding tool to install rings on a piston.
1. Check side clearance of compression rings with Feeler Gauge 303-D027 or equivalent by inserting it between pist
Gauge should slide freely around entire piston ring circumference without binding.
NOTE: If lower lands have high steps, piston should be replaced.
0.040-0.090
Piston ring side mm (0.0016-0.0035
clearance inch)
should be as top ring:
follows:-
- 0.030-0.080 mm (0.0012-0.0031 inch)2nd ring:
0.15limit:-
Service mm max (0.006 inch max) top ring:
2. If clearance is greater than service limit, replace piston ring. If clearance exceeds service limit after new piston rin
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Testing and Inspection > Page 2255
Piston Ring: Service and Repair
1. Remove piston rings using a piston ring expander.2. Clean and inspect piston.3. Verify piston ring end gap.
4. Install oil ring expander and two rails by hand. Position oil ring rail and expander gaps as shown.
5. Using a piston ring expander, install two compression rings as shown. Follow instructions on the piston ring packa
> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications

> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions
NOTE
> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 2263
Fuel Pressure Gauge
Special Tool(s)
> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications
Rocker Arm Assembly: Specifications

Ratio .................................................................................................................................................................................
> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 2267
Rocker Arm Assembly: Testing and Inspection

CLEANING
Clean all parts thoroughly using solvent. Make sure all oil passages are open.
INSPECTION
Inspect the pad at the valve end of the rocker arm for indications of scuffing or abnormal wear. If the pad is grooved,
Inspect rocker arm roller for abnormal wear. Rotate rocker arm roller to check for bearing wear. If any wear or dama
> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 2268
Rocker Arm Assembly: Service and Repair

REMOVAL
1. Remove valve covers.2. Position piston of cylinder being serviced at the bottom of its stroke and camshaft lobe at
3. Install Valve Spring Spacer 303-382 between valve spring coils to prevent valve stem seal damage.
CAUTION: If Valve Spring Spacer 303-382 is not used, valve spring retainer will hit valve stem seal and dama
4. Install Valve Spring Compressor 303-381 under camshaft and on top of valve spring retainer.5. Compress valve s
INSTALLATION
1. Apply clean Super Premium SHE 5W30 Motor Oil X0-5W30-4SP meeting Ford specification WSS-M2C153-G to
roller contact surfaces and valve tappet.
NOTE: Piston must be at the bottom of its stroke and camshaft at base circle.
4. Remove valve spring compressor and spacer.5. Repeat Steps 1 through 4 until all rocker arms are installed.6. Insta
> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications
Valve Cover: Specifications

Valve Cover Bolt/Stud Bolt .............................................................................................................................................
> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side
Valve Cover: Service and RepairRight Side
REMOVAL
1. Disconnect battery ground cable.2. Disconnect positive battery cable at battery and at power distribution box.3. Re
harness out of the way.
5. Disconnect vent hose from evaporative emission canister purge valve (EVAP canister purge valve) and position po
way.
6. Remove positive crankcase ventilation valve (PCV valve) from crankcase ventilation grommet and move out of th
INSTALLATION
1. Clean sealing surfaces of cylinder head, valve cover and engine front cover with Metal Surface Cleaner F4AZ-19A
Ford specification WSE-M5B392-A. Apply Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting
NOTE: Valve cover must be installed and tightened to specification within five minutes of applying sealer.
2. Position, and using Gasket anal Trim Adhesive F3AZ-19B508-B or equivalent meeting Ford specification ESR-M
glue new valve cover gasket into valve cover and install onto cylinder head.
> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2274

8-12 Nm (71-106 inch lbs.).
3. Install bolts and stud bolts into valve cover. Tighten studs and bolts to 4. Install positive crankcase ventilation valv
10. Connect battery ground cable.11. Start engine and check for leaks.
Valve Cover: Service and RepairLeft Side
REMOVAL
1. Remove
10. Remove air cleaner outlet
windshield wipertube.2. Disconnect battery ground cable.3. Relieve fuel system pressure and disconnect
governor.
11. Disconnect 42-pin connector and transmission harness connector from fuel charging wiring at power brake booste
wiring out of way.

12. Remove bolts and stud bolts retaining valve cover to cylinder head. Remove valve cover.
INSTALLATION
1. Clean sealing surfaces of cylinder head, engine front cover and valve cover with metal surface cleaner F4AZ- 19A
Ford specification WSE-M5B392-A in both places where engine front cover meets cylinder head.
NOTE: Valve cover must be installed and tightened to specification within five minutes of applying sealer.
2. Position and, using Gasket and Trim Adhesive F3AZ-19B508-B or equivalent meeting Ford specification ESR-M1
glue new valve cover gasket onto valve cover. Install valve cover onto cylinder head.
8-12 Nm (71-106 inch lbs.).
3. Install bolts and studs bolts into valve cover. Tighten studs and bolts to 4. Connect fuel charging wiring at 42-pin c
10. Lower vehicle.11. Connect fuel lines.12. Connect battery ground cable.13. Check oil level. Start engine and check
> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Testing and Inspection > Valve Guide Inner Diameter
Valve Guide: Testing and InspectionValve Guide Inner Diameter
Measure the inner diameter of the valve guides at the points shown.
If valve guide is not within specifications, ream the valve guide and install a valve with an oversize stem.
> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Testing and Inspection > Valve Guide Inner Diameter > Page 2281
Valve Guide: Testing and InspectionValve Stem to Guide Clearance
Check the valve stem-to-valve guide clearance of each valve in its respective valve guide with Dial Indicator with Brac
Install the tool on the valve stem until it is fully seated and firmly tighten the knurled setscrew. Permit the valve to drop
Position Rotunda Dial Indicator with Bracketry 100-002 or equivalent with its flat tip against the center portion of the t
> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Testing and Inspection > Valve Guide Inner Diameter > Page 2282
Valve Guide: Testing and InspectionValves, Select Fitting
7.02-7.04 mm (0.276-0.277 inch).If the valve stem-to-valve guide clearance exceeds the service clearance, replace the
In the case of valve stem-to-valve guide clearance, the service clearance is only intended as a diagnostic aid for engine
> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications
Valve Seat: Specifications

Valve Seats
Width - Intake .......................................................................................................................................................... 1

> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Testing and Inspection > Runout
Valve Seat: Testing and InspectionRunout
Check the valve seat runout with a valve seat runout gauge as illustrated. Follow the instructions of the gauge manufact
> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Testing and Inspection > Runout > Page 2288
Valve Seat: Testing and InspectionWidth

Using a seat width scale or a machinist's scale, measure the seat width. Narrow the seat, if necessary, to bring it within
If the valve seat width exceeds the maximum limit, remove enough stock from the top and/or bottom edge of the seat to
On the intake and exhaust seats, use a 60-degree angle grinding wheel to remove stock from the bottom of the seat (rais
> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Testing and Inspection > Page 2289
Valve Seat: Service and Repair
Measure the valve seat width. Reface the valve seats if the width is not within specification. Use Rotunda Valve Seat C
Refacing the valve seat should be closely coordinated with the refacing of the valve face so that the finished seat and va
Grind the valve seats to a true 45-degree angle. Remove only enough stock to clean up pits and grooves or to correct th
The finished valve seat should contact the approximate center of the valve face. Determine where the valve seat contac
To do this, coat the seat with Prussian Blue and set the valve in place. Rotate the valve with light pressure. If the blue is
> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Valve Spring Lock > Component Information > Service and Repair
Valve Spring Lock: Service and Repair

REMOVAL
1. Remove valve covers and rocker arms.2. Remove spark plug from applicable cylinder. 3. Position piston at top of
NOTE:
Failure of air pressure to hold the exhaust valve and intake valve closed while performing the following steps is a
4. Install an air line with an adapter in the spark plug hole and turn air supply ON.5. Install Valve Spring Spacer 303
7. Remove valve spring retainer keys, valve spring retainer and valve spring.
CAUTION:
If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve(s) t
8. Using locking pliers, remove valve stem seal.
9. Repeat Steps 2 through 8 until all necessary valve stem seals are removed.
INSTALLATION
1. Remove air pressure from spark plug adapter. Inspect the valve stem for damage. Rotate the valve and check the v
movement during rotation. Move the valve up and down through normal travel in the valve guide and check the s
NOTE: Piston must be at top dead center (TDC) of cylinder being serviced.
2. If the condition of the valve is satisfactory, apply clean Super Premium SAE 5W30 Motor Oil XO-5W30-QSP me
WSS-M2C153-G to the valve stem and hold the valve closed.
> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Valve Spring Lock > Component Information > Service and Repair > Page 2294

CAUTION: If the valve has been damaged, it will be necessary to remove the cylinder head for service.
2. Apply the air pressure within the cylinder.
3. Install new valve stem seal using Valve Stem Seal Replacer 303-383.4. Position valve spring and valve spring reta
10. Install rocker arms and valve covers.11. Start engine and check for leaks.
> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications
Valve: Specifications
Valve Arrangement (Front-to-Rear)
Left Hand ....................................................................................................................................................................

Valve Stem to Guide Clearance
Intake ................................................................................................................................................... 0.020-0.069 m

Valve Head Diameter
Intake ..........................................................................................................................................................................
Gauge Diameters ....................................................................................................................................... 42.5 and 32.0
Intake ........................................................................................................................................................... 6.995-6.

(0.015 Oversize)
Intake ....................................................................................................................................................... 7.376-7.35

(0.030 Oversize)
Intake ......................................................................................................................................................... 7.757-7.7

> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Inspection
Valve: Testing and InspectionInspection

Inspect the valve stem for bends and the end of the stem for grooves or scoring.
Inspect the valve face and the edge of the valve head for pits, grooves or scores. Inspect the stem for a bend condition a
Inspect the valve spring, valve spring retainers and valve spring retainer keys. Discard any damaged parts.
> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Inspection > Page 2300
Valve: Testing and InspectionSelect Fitting
7.02-7.04 mm (0.276-0.277 inch).If the valve stem-to-valve guide clearance exceeds the service clearance, replace the
In the case of valve stem-to-valve guide clearance, the service clearance is only intended as a diagnostic aid for engine
CAUTION:
0.254 mm (0.010 inch)The interference angle of the valve and seat should not be lapped out. Remove all grooves or sc
0.794 mm (0.031 inch)

If the valve face runout is excessive and/or to remove pits and grooves, reface the valves to a true 45-degree angle. Rem
If the valve and/or valve seat has been refaced, check the clearance between the rocker arm pad and the valve stem with
Valve: Testing and InspectionStem Diameter

Measure the diameter of each valve at the points shown.
If the stem diameter is not within specification, replace the valve.
6.995-6.975 mm (0.2753-0.2746 inch).The stem diameter of the intake valve should be within
6.970-6.949 mm (0.2744-0.2735 inch).The stem diameter of the exhaust valve should be within
Valve: Testing and InspectionStem to Guide Clearance
Check the valve stem-to-valve guide clearance of each valve in its respective valve guide with Dial Indicator with Brac
Install the tool on the valve stem until it is fully seated and firmly tighten the knurled setscrew. Permit the valve to drop
Position Rotunda Dial Indicator with Bracketry 100-002 or equivalent with its flat tip against the center portion of the t
> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Page 2303
Valve: Service and Repair

CAUTION: Discard any excessively worn or damaged valve train parts.
Minor pits or grooves may be removed. Discard severely damaged valves if the face runout cannot be corrected by refi
The valve refacing operation should be closely coordinated with the valve seat refacing operations so that the finished a
Make sure refacer grinding wheels are properly dressed. Refer to the illustration for critical valve dimensions.
> Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams
Drive Belt: Diagrams

Part 1 Of 2
> Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 2308

> Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 2309
Drive Belt: Description and Operation

(FEAD)
TheEngines equipped
4.6L (2V) with anare
OHC engines automatic
equippeddrive
withbelt tensionerFront
a multi-vee will not
Endrequire any drive
Accessory Drivebelt tension
belt adjustment
to ensure maximumfor
- Loose drive belts will result in slippage which may cause a noise complaint or improper accessory operation.
- Loose drive belts may result in operational problems like generators not delivering proper charge or other con
Drive -belts with automatic drive belt tensioners do not require adjustment.
NOTE:
-
When an accessory drive belt is replaced or reinstalled after a service procedure, the drive belt does not fully seat
Thisa vehicle
V-ribbedis serpentine accessory drive belt.
equipped with:-
- an automatic drive belt tensioner.
Replacement drive belts should be of the same type as originally installed.
Theatdrive
160,000
belt km (100,000
condition miles),
should be checked:-
- then every 24,140 km (15,000 miles).
> Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnost
Drive Belt: Initial Inspection and Diagnostic Overview
1. Verify the customer's original concern by operating the engine to duplicate the condition.2. Inspect to determine if
Drive belt noise or squeal.

Mechanical-
- Pulley misalignment or excessive pulley runout.
3. Inspect for drive belt cracking/chunking/wear.4. If inspection reveals obvious concern(s) that can be readily identi
Procedures
Drive Belt: Symptom Related Diagnostic Procedures
Part 1 Of 2
Part 2 Of 2
Drive Belt: Component Tests and General Diagnostics
Cracking/Chunking/Wear
Under severe operating conditions (high temperatures, low humidity), drive belt rib cracking can occur at less than 160
- is not a reason for concern.
- has no detrimental effect on drive belt performance. However, cracks running with backing are not acceptable.
The drive belt is still perfectly functional until rib chunking occurs. Drive belt chunking is where the rubber material ac
Drive Belt Chirp
pulley
Drive belt misalignment.
chirp is a regularly occurring chirping noise that occurs due to:-
- excessive pulley runout.
It can be a result of a damaged pulley or an improperly replaced pulley that was not properly aligned.
determine
To correct thebelt
drive areachirp:-
where the noise comes from.
- check each of the pulleys in that area with a straightedge to the crankshaft pulley.
- look for the accessory pulley to be out of position in the fore/aft direction or at an angle to the straightedge.
engine
Drive start-upis an intermittent noise that occurs when the drive belt slips on a pulley during certain condition
belt squeal
- rapid engine acceleration/deceleration
- A/C clutch engagement
Drive belt squeal can occur under the following conditions:-

theA/C
If the A/Cdischarge
system ispressure
overcharged.
goes above 2.895 kPa (420 psi). This can occur if:-
- the A/C condenser
engine airflow
cooling fan is engaging
is not blocked. fully at idle.
-
If any of the accessories are damaged, have a worn or damaged bearing or internal torsional resistance is abov
- If fluids get on the drive belt. This would include power steering fluid, engine coolant, engine oil and air cond
-
If fluid does get on the drive belt during service, clean the drive belt with soap and water and thoroughly rinse
-
If the drive belt is too long. This will allow the arm on the drive belt tensioner to go all the way to drive belt te
NOTE: The drive belt tensioner arm should rotate freely without binding. If the drive belt is worn or damaged, r
> Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 2314

- If the drive belt tensioner is worn or damaged, refer to Component Test. See: Drive Belt Tensioner/Testing an
> Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 2315
Drive Belt: Adjustments

The serpentine drive belt has an automatic drive belt tensioner and does not require adjustment.
Drive Belt: Service and Repair
WARNING: DO NOT ALLOW DRIVE BELT TENSIONER TO SNAP BACK AS DAMAGE TO DRIVE BE
NOTE:
Minor cracks in the V grooved portion of the drive belt are considered normal and acceptable. If the drive belt has ch
Conditions requiring drive belt replacement are rib chunk-out, severe glazing, frayed cords or other concerns. Replac
1. Rotate drive belt tensioner away from drive belt with a breaker bar installed in the 0.5 inch square hole in drive be


Part 1 Of 2
3. To install, position drive belt over pulleys. Make sure that all V grooves make proper contact with pulley as shown
NOTE:
- Make sure drive belt is properly installed on each pulley.
- When installing drive belt on pulleys, make sure that all grooves make proper contact with pulleys.
> Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications
Drive Belt Tensioner: Specifications

Drive Belt Tensioner to Engine Front Cover ...................................................................................................................
> Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 2321
Drive Belt Tensioner: Testing and Inspection
NOTE: The drive belt tensioner indicator mark inspection is done with the engine OFF at 160,000 km (100,000 mil
(FEAD)
Automatic tensioners are calibrated at the factory to provide the correct amount of tension to the belt, for a given Fro
The only mechanical check that need be made, if there is doubt as to the tensioner function, would be to remove the b
Locate the tab on the mounting plate of drive belt tensioner. The tab should be approximately between the stops of th
The automatic drive belt tensioner can be checked as follows:1. With the engine running, observe drive belt tensione
the engine is accelerated rapidly. If the drive belt tensioner moves constantly, a pulley or shaft is probably bent o
2. With engine off, check for proper routing of the drive belt.
Drive Belt Tensioner: Adjustments

(FEAD)The serpentine Front End Accessory Drive belt has an automatic drive belt tensioner and does not require adju
Drive Belt Tensioner: Service and Repair

1. Remove serpentine drive belt.2. Remove RH ignition coil from drive belt tensioner and engine front cover.3. Rem
20-30 Nm (15-22 ft. lbs.).4. To install, reverse removal procedure. Tighten drive belt tensioner retaining nut and bol
> Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise
Article No.99-11-1
06/14/99
^
^
CONTENTS
> Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins >
Comprehensive Noise/Vibration/Harshness Procedure > Page 2328

GENERAL PROCEDURES
Diagnostic Theory

Diagnostic Process

Glossary of Terms

Dynamic Balance







a.
c.
d.

-
Vibrate Software(R)

ChassisEAR
EngineEAR


Tracing Powder
d.

Diagnostic Process




2. Pre-Drive Check
important
^
^
^
^
5. Road Test
Note:
^

speed-related.
^
^
^

^

Steering Input Test
^
Brake Test
^
^
^
^

^ WARNING:
^ CAUTION:

^
WARNING:
CAUTION:
Note:
^
^ Start the engine.
^ CAUTION:

1. Static operation
^
2. While cranking
3. At idle
^
1.
1. Speed related
-
Idle vibration
-

-

-
-
Airvaries
Noise Leak with
wind/vehicle
2. Acceleration
-
4. Braking.
^
^
^
5. Clutching

6. Shifting
^
8. Cruising speeds
1.




































Pinpoint Tests































1. Open the hood.
2. Note:
Note:
4.
3. CAUTION:

3.
6.
7.

^



WARNING:
4. CAUTION:

WARNING:
WARNING:
Note:
1. WARNING:

CAUTION:
6.
^

Wheel Bearing Check
1. WARNING:

2. Note :

^
> Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise
Page 2423
Engine Mount: Technical Service BulletinsEngine Mounts - Unsatisfactory for Severe Conditions
Article No.01-1-1
01/22/01
ENGINE MOUNTS - REVISED ENGINE MOUNTS FOR SEVERE DUTY VEHICLES
This article is being republished in its entirety to update the model year coverage and part numbers.
ISSUEThe engine mounts on some vehicles may not exhibit satisfactory durability under severe operating conditions th
ACTIONIf service to the engine mounts is required, install new revised engine mounts which incorporate a heat shield.
PARTS BLOCK
OASIS CODES: 497000, 499000, 702000, 702100

> Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 2424
Engine Mount: Specifications

Front Engine Support Insulators ......................................................................................................................................

Transmission Retaining Bolts ....................................................................................................................................
> Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications
Idler Pulley: Specifications

Drive Belt Idler Pulley to Engine Front Cover ................................................................................................................
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications
Engine Oil Pressure: Specifications

Oil Pressure (HOT 1500 RPM) ........................................................................................................................................
> 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

Oil Level Indicator Tube to Cylinder Head .....................................................................................................................
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications > Page 2435
Engine Oil Dip Stick - Dip Stick Tube: Service and Repair
REMOVAL
1. Remove LH front engine support insulator.2. Remove bolt retaining oil level indicator tube to cylinder head and re
INSTALLATION
8-12 Nm (71-106 inch lbs.).

1. Inspect O-ring, lube with clean Super Premium SAE 5W30 Motor Oil XO-5W30-QSP and replace as needed. 2. R
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug > Component Information > Specifications
Engine Oil Drain Plug: Specifications

Oil Pan Drain Plug ...........................................................................................................................................................
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications
Engine Oil - Oil Recommendations/Applications
Article No.02-1-9
01/21/02
ENGINE - ENGINE OIL - RECOMMENDEDAPPLICATIONS FOR SAE 5W-20 AND SAE 5W-30MOTOR OILS -
FORD:1992-2002 CROWN VICTORIA1993-1994 TEMPO1993-1997 THUNDERBIRD1993-2002 ESCORT, MUST
LINCOLN:1991-2002 TOWN CAR1993-1998 MARK VIII1993-2002 CONTINENTAL2000-2002 LS1998-2002 NA
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
ISSUEFord Motor Company now recommends SAE 5W-20 viscosity grade for servicing most gasoline and flexible fu
ACTIONAll 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the recommended oil change
Testing has validated thisGRAND

MERCURY:1992-2002 viscosityMARQUIS1993-1994
grade can be used in many previous model
TOPAZ1993-1997 year vehicles. It is recommended
COUGAR1993-1999 ALL v
TRACER1993-2002
All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002 Vehicles" chart ar
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/
Applications > Page 2443

motor oil at the factory and should also be serviced with SAE 5W-20 oil.
NOTE
IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED. REFER TO TS
Parts Block
OTHER APPLICABLE ARTICLES: 99-8-16SUPERSEDES: 01-4-7WARRANTY STATUS: INFORMATION ONLY

Veh. App. Listing Approved For SAE 5W-20 Motor Oil

^ 1995-2000 2.0L Zetec Contour/Mystique
^ 1999-2002 2.0L Cougar
^ 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

^
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
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Pa
Engine Oil: Technical Service BulletinsMotor Oil - Viscosity Grade Recommendation
Article No.99-8-16
05/03/99
MOTOR OIL - SAE VISCOSITY GRADERECOMMENDATION - SERVICE TIP
LINCOLN-MERCURY:1989-1992 MARK VII1989-1994 TOPAZ1989-1997 COUGAR1989-1999 CONTINENTAL,
LIGHT TRUCK:1989-1990 BRONCO II1989-1996 BRONCO1989-1997 AEROSTAR, F SUPER DUTY1989-1999 E
ISSUEFord Motor Company now recommends SAE 5W-30 viscosity grade for servicing any Ford gasoline-powered v
ACTIONWhen servicing any Ford gasoline-powered vehicle, use SAE 5W-30 viscosity grade motor oil. Refer to the fo
Both SAE 10W-30 and SAE 5W-30 viscosity grade motor oils have been recommended in the past depending on vehic
Tests have proven SAE 5W-30 viscosity grade motor oil provides the optimum protection and benefits for Ford gasolin
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
XO-5W30-QSP 5W-30 Motorcraft Super Premium Motor Oil

> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications
Engine Oil: Capacity Specifications
Engine Oil
Capacity ...............................................................................................................................................................................
NOTE: Listed capacities are approximate. Check fluid level after filling.
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2449
Engine Oil: Fluid Type Specifications
Engine Oil Type
Type .....................................................................................................................................................................................
Viscosity .............................................................................................................................................................................
NOTE: Must meet Ford Specification M2C-153-F

> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications
Oil Filter: Specifications

Filter to Adapter .......................................................................................................................................... 1/2 turn afte
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications > Page 2453
Oil Filter: Service and Repair

REMOVAL
1. Raise vehicle on a hoist. 2. Position a drain pan under oil bypass filter area.3. Unscrew the oil bypass filter from o
5. If removal of the oil filter adapter is required, proceed with the following:
Clean
a. On and inspect
trailer-tow the sealing
and police surfaces
option of the
equipped oil filter
vehicles, adapter gasket
disconnect the oil and cylinder
supply block.hoses from the oil coo
and return
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications > Page 2454

INSTALLATION
20-30 Nm (15-22 ft. lbs.).
a. Tighten bolts to b. Install the lower radiator hose onto the oil filter adapter. Install the hose clamp securely.c. C
3. Coat rubber seal of oil bypass filter with clean Super Premium SAE 5W30 Motor Oil XO-5W30-QSP.
NOTE:
The oil bypass filter has a 22 mm metric thread and an anti-drain back valve. Make sure the replacement oil bypa
4. Install oil bypass filter on oil filter adapter until rubber seal contacts sealing surface of oil filter adapter.5. Tighten
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Bypass Filter Adapter <--> [Oil Filter Adapter] > Component Information > Specifications
Oil Bypass Filter Adapter: Specifications

Oil Filter Adapter Bolts .......................................................................................................................................................
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Bypass Filter Adapter <--> [Oil Filter Adapter] > Component Information > Locations > Non Trailer Tow and Police Op
Oil Filter Adapter

> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Bypass Filter Adapter <--> [Oil Filter Adapter] > Component Information > Locations > Non Trailer Tow and Police Op
Oil Bypass Filter Adapter: LocationsTrailer Tow and Police Option
Oil Filter Adapter (Trailer Tow and Police Option)

Oil Filter Adapter (Trailer Tow and Police Option)
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Bypass Filter Adapter <--> [Oil Filter Adapter] > Component Information > Service and Repair > Removal
Oil Bypass Filter Adapter: Service and RepairRemoval
1. Raise vehicle on a hoist. 2. Position a drain pan under oil bypass filter area.
3. Unscrew the oil bypass filter from oil filter adapter using an oil-filter wrench.4. Clean the oil bypass filter sealing
a. On trailer-tow and police option equipped vehicles, disconnect the oil supply and return hoses from the oil coo
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Bypass Filter Adapter <--> [Oil Filter Adapter] > Component Information > Service and Repair >
Removal > Page 2463

f. Clean and inspect the sealing surfaces of the oil filter adapter gasket and cylinder block.
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Bypass Filter Adapter <--> [Oil Filter Adapter] > Component Information > Service and Repair > Removal > Page 2464
Oil Bypass Filter Adapter: Service and RepairInstallation

2. Install new oil filter adapter gasket, oil filter adapter and retaining bolts.
20-30 Nm (15-22 ft. lbs.)a. Tighten bolts to .
b. Install the lower radiator hose onto the oil filter adapter. Install the hose clamp securely.
c. Connect the fuel charging wiring to the oil pressure sensor and wiring bracket.
d. On trailer tow and police option equipped vehicles, connect the oil supply and return hoses from the oil cooler
SAE 5W303. Coat rubber seal of oil bypass filter with clean Super Premium Motor Oil.
NOTE: 22 mm
22 mmThe oil bypass filter has a metric thread and an anti-drain back valve. Make sure the replacement oil bypa
4. Install oil bypass filter on oil filter adapter until rubber seal contacts sealing surface of oil filter adapter.
5. Tighten an additional three-quarter turn after seal contact.
6. Lower vehicle.
SAE 10W307. Check oil level and fill crankcase with clean Super Premium Motor Oil to specified level.
8. If required, fill cooling system.
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Bypass Filter Adapter <--> [Oil Filter Adapter] > Component Information > Service and Repair >
Removal > Page 2465

9. Start engine and check for leaks.
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications
Oil Pan: Specifications

Oil Pan to Cylinder Block
First in
Tighten step: 20 Nm (14 Ft. Lbs.)
2 steps:-
- Second step: rotate 60 degrees.
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2469
Oil Pan: Description and Operation
Theisoil
stamped
pan:- steel and bolts to the bottom of the engine cylinder block and engine front cover.
- acts as a reservoir holding lubrication that is pumped through the engine by the oil pump after engine start up.
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2470
Oil Pan: Testing and Inspection

CLEANING
CAUTION: Do not damage the Low oil level sensor (if equipped) when cleaning the oil pan.
Scrape any dirt or metal particles from the inside of the oil pan. Scrape all old gasket material from the gasket surfac
INSPECTION
Check the oil pan for cracks, holes or damaged drain plug threads. Check the gasket surface for damage caused by ov
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal
Oil Pan: Service and RepairRemoval
1. Disconnect battery ground cable.2. Remove air cleaner outlet tube.3. Drain cooling system and remove fan blade a
11-16 Nm (8-12 ft. lbs.).

10. Disconnect heater water hose.11. Remove nut retaining ground strap to RH cylinder head.12. Remove upper stud
18. Lower exhaust and secure to crossmember in positions shown with wire.19. Position a screw-type jackstand and a
23. Remove bolts retaining oil pan to engine. Remove oil pan.
NOTE:
It may be necessary to loosen (DO NOT REMOVE) the two nuts on transmission support insulator. With a screw
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal > Page 2473

24. If necessary, remove two bolts retaining oil pump screen cover and tube to oil pump and remove bolt retaining oil
main bearing stud spacer. Remove oil pump screen cover and tube.
Oil Pan: Service and RepairInstallation
1. Clean oil pan and inspect for damage.2. Clean sealing surfaces of engine front cover crankshaft rear oil seal and re
NOTE:
3. Inspect oil pump screen cover and tube and replace O-ring.4. If removed, position oil pump screen cover and tube
8-12 Nm (71-106 inch lbs.).6. Tighten oil pump screen cover and tube-to-oil pump bolts to Tighten oil pump screen
20-30 Nm ( 15-22 ft. lbs.).stud spacer bolt to

7. Position new oil pan gasket on oil pan.8. Apply Silicone Gasket and Sealant F6AZ-19562-AA or equivalent where
20 Nm ( 14 ft. lbs.)
retainer meets cylinder block. Position oil pan on engine and install retaining bolts. Tighten bolts in sequence to
9. Position screw-type jackstand and block of wood under oil pan rearward of oil drain hole.
20-30 Nm (15-22 ft. lbs.).10. Raise engine enough to remove wooden blocks.11. Lower engine onto front engine supp

NOTE:
Two through-bolts are required on LH front engine support insulator and one through-bolt is required on RH fron
20-30 Nm (15-22 ft. lbs.). NOTE: 13. Install bolt retaining RH front engine support insulator to lower front sub-fram
27-41 Nm (20-30 ft. lbs.).Remove wire and position exhaust system to both exhaust manifolds. Install four nuts a
20-30 Nm (15-22 ft. lbs.).15. Replace oil bypass filter.16. Lower vehicle.17. Install heater blower motor switch resist
20-30 Nm (15-22 ft. lbs.).ground strap on stud and tighten nut to
19. Connect heater water hose.20. Connect 42-pin connector and eight-pin transmission harness connector at power br
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications

> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications > Page 2480
Oil Pressure Switch

Theisoil
threaded
switch:-
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > With Conventional Instrume
Oil Pressure Warning Lamp/Indicator: Description and OperationWith Conventional Instrument Cluster
Oil pressure indication system consists of the following:
- oil pressure gauge
- oil pressure switch (located in the engine block)
- necessary circuitry
Oil Pressure Gauge The oil pressure gauge is a part of Engine Coolant Temperature Gauge assembly.
The90 degreeItgauge
magnetic consists
has of
thetwo primaryfeatures:-
following coils, one of which is wound at a angle to the other one.
- The coils form a magnetic field which varies in direction according to the resistance of the oil pressure switch
- A permanent magnet, to which a shaft and pointer are attached, rotates to align to this primary field, resulting
- The bobbin/coil assembly is pressed into a metal housing. The bobbin has two holes for dial mounting.
- There is no adjustment, calibration or maintenance required for these gauges.
CAUTION: Do not remove magnetic gauge pointers; the gauge cannot be recalibrated.
Oil Pressure Switch

Theisoil
threaded
switch:-
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > With Conventional Instrume
Oil Pressure Warning Lamp/Indicator: Description and OperationWith Electronic Instrument Cluster
Oil Pressure Indication Switch
Theoil
oilpressure
pressureswitch on the
indication engine.
system consists of:-
- engine oil pressure warning indicator in the instrument cluster.
Low Oil Pressure Warning

If the oil pressure drops below the normal range, the oil can symbol will light and a tone will sound to alert drive
Oil Pressure Switch
The oil pressure switch is threaded into the cylinder block. The oil pressure switch reacts to the pressure of the en
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Specifications > Oil Pump Pick Up
Oil Pick Up/Strainer: SpecificationsOil Pump Pick Up

Screen Cover and Tube to Oil Pump Bolt ........................................................................................................................

> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Specifications > Oil Pump Pick Up > Page 2490
Oil Pick Up/Strainer: SpecificationsOil Strainer, Engine

Screen Cover and Tube to Oil Pump Bolt ........................................................................................................................

> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair > Oil Pump Pick Up
Oil Pick Up/Strainer: Service and RepairOil Pump Pick Up
Removal
11-16 Nm (8-12 ft. lbs.).
19. Position a screw-type jackstand and a block of wood under oil pan rearward of oil drain hole.20. Raise engine app
NOTE: It may be necessary to loosen (DO NOT REMOVE) the two nuts on transmission support insulator. Wit
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair > Oil Pump Pick Up > Page 2493

the extension housing of the transmission slightly to remove oil pan.
Installation
NOTE:
8-12 Nm (71-106 inch lbs.).3. Inspect oil pump screen cover and tube and replace O-ring.4. If removed, position oil
20 Nm ( 14 ft. lbs.)

10. Raise engine enough to remove wooden blocks.
20-30 Nm (15-22 ft. lbs.).11. Lower engine onto front engine support insulator and remove jack.12. Install front engin
NOTE:
20-30 Nm (15-22 ft. lbs.).13. Install bolt retaining RH front engine support insulator to lower front sub-frame. Tighte

NOTE: 14. Make sure exhaust system clears No. 3 crossmember. Adjust as necessary.
Oil Pick Up/Strainer: Service and RepairOil Strainer, Engine
Removal
11-16 Nm (8-12 ft. lbs.).
19. Position a screw-type jackstand and a block of wood under oil pan rearward of oil drain hole.20. Raise engine app
NOTE: It may be necessary to loosen (DO NOT REMOVE) the two nuts on transmission support insulator. Wit

the extension housing of the transmission slightly to remove oil pan.
Installation
NOTE:
8-12 Nm (71-106 inch lbs.).3. Inspect oil pump screen cover and tube and replace O-ring.4. If removed, position oil
20 Nm ( 14 ft. lbs.)

10. Raise engine enough to remove wooden blocks.
20-30 Nm (15-22 ft. lbs.).11. Lower engine onto front engine support insulator and remove jack.12. Install front engin
NOTE:
20-30 Nm (15-22 ft. lbs.).13. Install bolt retaining RH front engine support insulator to lower front sub-frame. Tighte

NOTE: 14. Make sure exhaust system clears No. 3 crossmember. Adjust as necessary.
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications
Engine Oil Pressure: Specifications

Oil Pressure (HOT 1500 RPM) ........................................................................................................................................
> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Recalls: > 05N04 > Dec > 05 > Campaign - Intake Manifold Extended
05N04Technical Service Bulletin #

> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Recalls: > 05N04 > Dec > 05 > Campaign - Intake
Manifold Extended Warranty Coverage > Page 2512

OASIS ACTIVATED? Yes. Affected vehicles will be activated in OASIS on December 14, 2005.
FSA VIN LIST ACTIVATED? No.
STOCK VEHICLES
Do not perform this program unless the affected vehicle exhibits the covered condition (fix only if the coolant crossove
SOLD VEHICLES
Owners with affected vehicles that exhibit the covered condition will be directed to dealers for repairs. Owners who ha
RELATED DAMAGE

It is highly unlikely that you will encounter related damage while performing this repair but if a related damage conditi
^
If a condition exists that requires additional labor to complete the repair call the Special Service Support Center to r
^
OWNER REFUNDS
Program 05N04 covers one intake manifold replacement per vehicle. Program 46B01 covers one refund per vehicle
^
Ford Motor Company will only refund owner-paid repairs covered by 46B01 if the repair was performed prior to D
^ The repair must have been completed within 7 years of the warranty start date to be eligible for a refund.
RENTAL VEHICLES
^ 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. (Requires prior app


LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Parts will not be direct shipped for this program. Order your parts requirements through normal order processing chann
RECALL PARTS ASSISTANCE
There are three methods to use for questions or assistance regarding recall parts:
^ Parts Support Center

^ E-mail
^ FAX Number
When contacting the Parts Support Center via phone FAX or E-mail for a question or concern please provide:
^ Dealer Name and P & A code
^ Contact Name
^ Phone number and E-mail address
^ FSA # : Customer Satisfaction Program 05N04
^ Include a VIN #
^ Part number that you have a question / concern with
DEALER PRICE
For latest prices refer to DOES II.
Affected intake manifolds are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPA
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures."
OVERVIEW
This program involves either:
A)
inspecting the intake manifold part number to determine if the owner is eligible for reimbursement for a pre
B)
inspecting the intake manifold coolant crossover directly behind the alternator for leakage in the event the o
Proceed to the appropriate inspection procedure.
PART NUMBER INSPECTION
NOTE:
The part number is molded into the intake manifold and is located between two (2) runners on the driver side of the
^
On most affected vehicles, the throttle body points toward the driver side of the vehicle. The part number will be
^
On applications where the throttle body is pointing toward the right side of the vehicle, the part number is still lo
1. Remove the engine appearance cover, if equipped.

2. Locate the area on the intake manifold where the part number is to be found. See Figure 1.
3. NOTE
: Thorough cleaning of the area is required in order to accurately read the part number prefix and suffix. Wrap a s
Clean the area between the two (2) runners by first blowing any dirt or foreign material away using compressed a
4. Read and record the intake manifold part number.

^ If the part number on the manifold matches the part numbers listed, the vehicle is not eligible for a refund wit

^ If the part number is different than the numbers listed below, the vehicle is eligible for a refund without a rece
COOLANT LEAKAGE INSPECTION
1. NOTE
: To properly inspect the intake manifold you must look down behind the alternator. Inspect the coolant crossove
^
If seepage IS present, the intake manifold MUST be replaced. Refer to the appropriate Workshop Manual, Sec
^ If seepage is NOT present, no service action is required.

Owner Letter
Owner Letter not applicable.
> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Recalls: > 01M02 > Mar > 01 > Campaign - Intake Manifold Addition
01M02Technical Service Bulletin #
Campaign - Intake Manifold Additional Warranty Coverage

01M02
Additional Coverage on Certain 4.6L SOHC Intake Manifolds Installed in the Following Vehicles:
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIII^
^ Owner Letter
> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Recalls: > 01M02 > Mar > 01 > Campaign - Intake
Manifold Additional Warranty Coverage > Page 2522


Additional Coverage on Certain 4.6L SOHC Intake Manifolds Installed In: - Certain 1996 through 2001 Model Year C
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
NOTE:
On an "M" program, the VIN number will remain in OASIS until the time limit of the program expires.

OWNER REFUNDS
Ford Motor Company will only refund owner-paid repair made before the date of the Owner Letter (or after the date of
Program Code: 01M02Misc. Expense: REFUNDMisc. Expense: ADMIN

Misc. Expense: 0.2 Hr.
Refer to ACESII manual for refund information.
RENTAL CARS
Rental vehicle coverage is not included under this program.
LABOR ALLOWANCES
PLEASE NOTE:
The labor times in the above table reflect the latest corporate standards for determining labor times. These times app
PARTS REQUIREMENTS

Parts will not be direct shipped for this program. Order your parts requirement through normal order processing channe
DOR/COR NUMBER
DOR/COR Number 50218 identifies parts ordered for this campaign through the Recall Hotline (1-800-325-5621).

DEALER PRICE
For latest prices, refer to:
^ DOES II
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Po
INSPECTION
NOTE:
To properly inspect the intake manifold you must look down behind the alternator.
1. Inspect the coolant crossover area of the intake manifold as shown in Figure 1 for engine coolant seepage.
^
If seepage IS present, the intake manifold MUST be replaced. Refer to the appropriate Workshop Manual sec



> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Recalls: > 97M91 > Mar > 99 > Campaign - Intake Manifold Replacem
Campaign - Intake Manifold Replacement

97M91
Certain 1996-1998 Crown Victoria Taxi, Town Car Limo Prep & Livery Package, 1996-1997 Thunderbird, Cougar and
^ Dealer Letter
^
Administrative
^ Refund Codes
^
Labor Allowances
Attachment II^
^
TechnicalIII^

Manifold Replacement > Page 2532


Attachment I - Admin Info/Refund Codes
NOTE:
On an "M" program, after a claim has been submitted on an affected vehicle, the VIN number will remain in OASIS
OWNER REFUNDS

See ACESII Manual, Section 3 for submission procedures.
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts Ordering InformationParts will not be direct shipped for this program. Order your parts requirements through nor
REMOVED PARTS RETURNHold the removed intake manifold until the claim is paid and the Parts Department rece
^ DOES II

CLAIMS PREPARATION
Enter using DWE. Use code information shown below
^ Program Code: 97M91
^ Labor Operation: See Above
Affected Vehicles
INTAKE MANIFOLD INSPECTION/REPLACEMENT
AFFECTED VEHICLES:1996-1998 CROWN VICTORIA TAXI VEHICLES WITH 4.6L SOHC ENGINES BUILT A
1996-1998 TOWN CAR LIMO PREP AND LIVERY PACKAGE VEHICLES WITH 4.6L SOHC ENGINES BUILT
1996-1997 THUNDERBIRD AND COUGAR VEHICLES WITH 4.6L SOHC ENGINES BUILT AT THE LORAIN A
1996-1997 MUSTANG VEHICLES WITH 4.6L SOHC ENGINES BUILT AT THE DEARBORN ASSEMBLY PLAN
Inspection
INSPECTION
Inspect intake manifold in area shown in Figure 1 for coolant seepage. If seepage is present, the intake manifold must b

INTAKE MANIFOLD REPLACEMENT
NOTE:
THE FIGURES ILLUSTRATED IN THE FOLLOWING TECHNICAL INSTRUCTIONS REPRESENT A 1997 C
Removal
REMOVAL
1. Install memory saver, then disconnect battery ground cable.
2. Remove cover from throttle body.
3. Drain cooling system.
4. Relieve fuel system pressure as follows:
^ Connect Multiport Fuel Injection (MFI) Fuel Pressure Gauge T80L-9974-B to fuel pressure relief valve on the
^ Open manual valve on gauge to relieve fuel system pressure.
^ Remove gauge from relief valve.
5. Remove air cleaner outlet tube.
6.
If equipped with ignition wires, disconnect the ignition wires from spark plugs and routing clips. If equipped with
7. Remove PCV valve and hose from engine.


8.
Disconnect fuel charge wiring harness from right side fuel injectors, Engine Coolant Temperature (ECT) sender a
9. Disconnect heater hose from right rear corner of intake manifold. See to Figure 3.
10. Remove throttle/speed control cable routing bracket. See to Figure 3.
11. Disconnect EGR tube from EGR valve. See to Figure 3.
12. Disconnect vacuum line from EVAP solenoid. See Figure 3.
13. Disconnect two (2) vacuum lines from top of throttle body adapter.

14. Disconnect main engine wiring harness pushpin from rear of intake manifold. See Figure 4.
15. Remove drivebelt from alternator.
16. Remove retainers from alternator upper support bracket, then slightly raise bracket. Refer to Figure 5.

17. Disconnect all alternator electrical connectors. See Figure 5.
18. Position alternator upper support bracket and ignition wires (if equipped) away from intake manifold.
19. Detach alternator wiring harness from intake manifold~ then position wiring harness aside.
20. Remove alternator from vehicle.
21. Disconnect radiator hose from thermostat housing.


22. Disconnect throttle and speed control cables from throttle body.See to Figure 6. Position cable away from intake
23. Disconnect fuel charge wiring harness from left side fuel injectors, Engine Coolant Temperature (ECT) sensor and
24. Disconnect fuel lines at spring clips. See Figure 6.


25.
Detach two (2) wiring harnesses from clip on left rear of intake manifold. See Figure 7. Push both harnesses towa
26. Disconnect Throttle Position (TP) sensor electrical connector.
27. Disconnect Idle Air Control (IAC) sensor electrical connector.


28. Unclip fuel charge wiring harness from studs on left side valve cover. Position wiring harness away from intake m
29. Remove intake manifold retaining bolts.
30. With an assistant's help, remove intake manifold assembly.
Installation
1. Transfer all necessary components to new intake manifold.
2. Clean intake manifold to cylinder head gasket surface.
3. Install new intake manifold gaskets.


4.
With an assistant's help, install intake manifold assembly. Tighten screws in sequence shown in Figure 9, to 20-3
5. Clip fuel charge wiring harness to studs on left side valve cover.
6. Connect Idle Air Control (IAC) motor electrical connector.
7. Connect Throttle Position (TP) sensor electrical connector.
8. Attach two (2) wiring harnesses to clip on left rear of intake manifold.
9. Connect fuel lines to spring clips.
10. Connect fuel charge wiring harness to left side fuel injectors, Engine Coolant Temperature (ECT) sensor and reta
11. Connect throttle and speed control cables to throttle body.
12. Connect radiator hose to thermostat housing.
13. Install alternator. Tighten bolts to 20-30 Nm (15-22 lb/ft).
14. Position alternator upper support bracket close to installed position, then connect all alternator electrical connecto
15. Install alternator upper support bracket. Tighten bolts to 8-12 Nm (71-106 lb/in).
16. Attach alternator wiring harness to intake manifold.
17. Install drivebelt on alternator.
18. Connect main engine wiring harness pushpin to rear of intake manifold.
19. Connect two (2) vacuum lines to top of throttle body adapter.
20. Connect vacuum line to EVAP solenoid.
21. Connect EGR tube to EGR valve. Tighten nut to 35-45 Nm (26-33 lb/ft).

22. Clip throttle/speed control cables on routing bracket.
23.
Clip fuel charge wiring harness to fuel supply manifold, then connect right side fuel injectors, Engine Coolant Te
24. Install PCV valve and hose.
25.
If equipped with ignition wires, connect the ignition wires to spark plugs and routing clips. If equipped with a coi
26. Install air cleaner outlet tube.
28. Fill cooling system as follows:
^ Fill coolant recovery reservoir with 50/50 mixture of antifreeze and water until the mixture flows out of the di
^ Connect heater hose to right rear corner of intake manifold.
^ Fill coolant recovery reservoir to below the filler neck seat.
^ Place heater temperature selector in Maximum heat position.
^ Install pressure relief cap.
^ Start and run engine until normal operating temperature (thermostat opens) is reached.
^ Stop engine and allow to cool.
^ Refill reservoir to the COLD FULL LEVEL.
29. Check engine for fuel and cooling system leaks.



> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Recalls: > 99M01 > Mar > 99 > Campaign - Intake Manifold Cracking
Campaign - Intake Manifold Cracking

99M01
Certain 1997 and 1998 Crown Victoria Police Interceptor Vehicles with 4.6L SOHC Engines - Intake Manifold Additio
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIII^

Manifold Cracking > Page 2551


NOTE:
OWNER REFUNDS

LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your part requirements through normal order processing channe
REMOVED PARTS RETURN
Hold the removed intake manifold until the claim is paid and the Parts Department receives WPRC "parts disposition in
^ DOES II

EXCESS STOCK RETURN
CLAIMS PREPARATIONEnter using DWE
Use code information shown below:

Affected Vehicles, Inspection and Replacement

AFFECTED VEHICLES:1997 AND 1998 CROWN VICTORIA POLICE INTERCEPTOR VEHICLES WITH 4.6L S
INSPECTION
NOTE:
THE FIGURES ILLUSTRATED IN THE TECHNICAL INSTRUCTIONS REPRESENT A 1997 CROWN VICTO
Removal

^
Connect Multiport Fuel Injection (MFI) Fuel Pressure Gauge T8OL-9974-B or equivalent to fuel pressure relief
6.
8.

9. Disconnect heater hose from right rear corner of intake manifold. Refer to Figure 3.
10. Remove throttle/speed control cable routing bracket. Refer to Figure 3.
11. Disconnect EGR tube from EGR valve. Refer to Figure 3.



16. Remove retainers from alternator upper support bracket, then slightly raise bracket. See Figure 5.
19. Detach alternator wiring harness from intake manifold, then position wiring harness aside.


22. Disconnect throttle and speed control cables from throttle body. See Figure 6. Position cable away from intake m
23. Disconnect fuel charge wiring harness from left side fuel injectors, Engine Coolant Temperature (ECT) sensor an


25.
27. Disconnect Idle Air Control (IAC) motor electrical connector.
Installation


4.
13. Install alternator. Tighten bolts to 20-30 Nm (15-22 lb-ft).
15. Install alternator upper support bracket. Tighten bolts to 8-12 Nm (71-106 lb-in).
21. Connect EGR tube to EGR valve. Tighten nut to 35-45 Nm (26-33 lb-ft).


23.
25.
^ Fill coolant recovery reservoir with 50/50 mixture of antifreeze and water until the mixture flows out of the disc
29. Check engine for fuel and cooling system leak.



> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest: > 02-2-2 > Feb > 02 > Intake Manifold - Cross-Ove
Intake Manifold: Customer InterestIntake Manifold - Cross-Over Channel Coolant Seepage
Article No.02-2-2
02/04/02
COOLANT - COOLANT SEEPAGE AT INTAKE MANIFOLD CROSS-OVER - VEHICLES EQUIPPED WITH
^
ENGINE - 4.6L 2V - COOLANT SEEPAGE AT INTAKE MANIFOLD CROSS-OVER
FORD:1996-1997 THUNDERBIRD1996-2001 CROWN VICTORIA, MUSTANG2002 EXPLORER
MERCURY:1996-1997 COUGAR1996-2001 GRAND MARQUIS
ISSUESome vehicles may exhibit an Intake Manifold crossover (first runner) coolant seepage condition. This may be c
ACTIONInspect the suspect Intake Manifold for a coolant leak at the first runner cross-over area (Figure 1). If coolant
4.6L 2V INTAKE MANIFOLD
INSPECTION/REPLACEMENT
Refer to Figure 1 for inspection of coolant seepage.
> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest: > 02-2-2 > Feb > 02 > Intake
Manifold - Cross-Over Channel Coolant Seepage > Page 2570

If seepage is found, order one of the following Service Kits to repair.
> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest: > 02-2-2 > Feb > 02 > Intake
Manifold - Cross-Over Channel Coolant Seepage > Page 2571

> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 05N04 > Dec >
Extended Warranty Coverage

> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: >
05N04 > Dec > 05 > Campaign - Intake Manifold Extended Warranty Coverage > Page 2577

STOCK VEHICLES
SOLD VEHICLES
RELATED DAMAGE

^
^
OWNER REFUNDS
^
RENTAL VEHICLES


LABOR ALLOWANCES

^ E-mail
^ FAX Number
^ Contact Name
^ Include a VIN #
DEALER PRICE
OVERVIEW
A)
B)
NOTE:
^
^

3. NOTE


1. NOTE
^

Owner Letter
> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 02-2-2 > Feb >
Channel Coolant Seepage
Intake Manifold: All Technical Service BulletinsIntake Manifold - Cross-Over Channel Coolant Seepage
Article No.02-2-2
02/04/02
^
02-2-2 > Feb > 02 > Intake Manifold - Cross-Over Channel Coolant Seepage > Page 2587

02-2-2 > Feb > 02 > Intake Manifold - Cross-Over Channel Coolant Seepage > Page 2588

> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 01M02 > Mar >
Additional Warranty Coverage

01M02
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIII^
^ Owner Letter
01M02 > Mar > 01 > Campaign - Intake Manifold Additional Warranty Coverage > Page 2593


OASIS
NOTE:

OWNER REFUNDS

RENTAL CARS
LABOR ALLOWANCES
PLEASE NOTE:
PARTS REQUIREMENTS

DOR/COR NUMBER

DEALER PRICE
^ DOES II
EXCESS STOCK RETURN
INSPECTION
NOTE:
^



Replacement

97M91
^ Dealer Letter
^
Administrative
^ Refund Codes
^
Labor Allowances
Attachment II^
^
TechnicalIII^

97M91 > Mar > 99 > Campaign - Intake Manifold Replacement > Page 2603


NOTE:
OWNER REFUNDS

LABOR ALLOWANCES
PARTS REQUIREMENTS
^ DOES II

CLAIMS PREPARATION
Affected Vehicles
Inspection
INSPECTION

NOTE:
Removal
REMOVAL
6.


8.






25.


Installation


4.

23.
25.



Cracking

99M01
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIII^

99M01 > Mar > 99 > Campaign - Intake Manifold Cracking > Page 2622


NOTE:
OWNER REFUNDS

LABOR ALLOWANCES
PARTS REQUIREMENTS
^ DOES II

EXCESS STOCK RETURN


INSPECTION
NOTE:
Removal

^
6.
8.








25.
Installation


4.


23.
25.



> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 98-25-8 > Dec > 98
Buzzing Noise On Right Turns
Intake Manifold: All Technical Service BulletinsIntake Manifold - Cross-Over Channel Coolant Seepage
Article No.02-2-2
02/04/02
^
> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 98-
25-8 > Dec > 98 > Steering Wheel - Vibration/Buzzing Noise On Right Turns > Page 2641

> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 98-
25-8 > Dec > 98 > Steering Wheel - Vibration/Buzzing Noise On Right Turns > Page 2642

> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 05N04 > Dec > 05
Extended Warranty Coverage

> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: >

STOCK VEHICLES
SOLD VEHICLES
RELATED DAMAGE

^
^
OWNER REFUNDS
^
RENTAL VEHICLES


LABOR ALLOWANCES

^ E-mail
^ FAX Number
^ Contact Name
^ Include a VIN #
DEALER PRICE
OVERVIEW
A)
B)
NOTE:
^
^

3. NOTE


1. NOTE
^

Owner Letter
> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 01M02 > Mar > 01
Additional Warranty Coverage

01M02
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIII^
^ Owner Letter


OASIS
NOTE:

OWNER REFUNDS

RENTAL CARS
LABOR ALLOWANCES
PLEASE NOTE:
PARTS REQUIREMENTS

DOR/COR NUMBER

DEALER PRICE
^ DOES II
EXCESS STOCK RETURN
INSPECTION
NOTE:
^



Replacement

97M91
^ Dealer Letter
^
Administrative
^ Refund Codes
^
Labor Allowances
Attachment II^
^
TechnicalIII^



NOTE:
OWNER REFUNDS

LABOR ALLOWANCES
PARTS REQUIREMENTS
^ DOES II

CLAIMS PREPARATION
Affected Vehicles
Inspection
INSPECTION

NOTE:
Removal
REMOVAL
6.


8.






25.


Installation


4.

23.
25.



Cracking

99M01
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIII^



NOTE:
OWNER REFUNDS

LABOR ALLOWANCES
PARTS REQUIREMENTS
^ DOES II

EXCESS STOCK RETURN


INSPECTION
NOTE:
Removal

^
6.
8.








25.
Installation


4.


23.
25.



> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2701
Intake Manifold: Specifications
Torque Sequence
Installation Sequence - Gasoline Engine
Intake Manifold To Cylinder Head Bolt ..........................................................................................................................
> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Intake Manifold: Initial Inspection and Diagnostic Overview

Cleaning
CAUTION:
- Remove all filings and foreign matter that may have entered the intake manifold as a result of service or dama
- Check and make sure that all pressed-in core plugs and tubes are fully seated and tight or damage to the engin
Remove all gasket material from the machined surfaces of the intake manifold. Clean the intake manifold in a suitab
INSPECTION
Inspect the intake manifold for cracks, damaged gasket surfaces or other damage that would make it unfit for further
> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2704
Intake Manifold: Component Tests and General Diagnostics
Intake Manifold Vacuum Test
Bring the engine to normal operating temperature. Connect Rotunda Vacuum / Pressure Tester 164-R0253 or equivalen
51-74 kPa (15-22 in Hg)

4.0193 kPa (1.0 in. Hg)The vacuum gauge should read between depending upon the engine condition and the altitude
The reading should be quite steady. If necessary, adjust the gauge damper control (where used) if the needle is flutterin
Interpreting Vacuum Gauge Readings
A careful study of the vacuum gauge reading while the engine is idling will help pinpoint trouble areas. Always conduc
Most vacuum gauges have a NORMAL band indicated on the gauge face.
The following are potential gauge readings. Some are normal; others should be investigated further:
Vacuum Gauge Readings
NORMAL READING: 51-74 kPa (15 and 22 in. Hg)

NORMAL READING DURING RAPID ACCELERATION AND DECELERATION:1. Needle between and
needle), the needle will drop to a low (not to zero) reading. When the throttle is suddenly released, the needle wil
> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2705

normal reading.
NORMAL FOR HIGH-LIFT CAMSHAFT WITH LARGE OVERLAP:3. Needle will register as low as 51 kPa
relatively steady. Some oscillation is normal.
WORN RINGS OR DILUTED OIL: 0 kPa (0 in. Hg).4. When the engine is accelerated (dotted needle), the need
74 kPa (22 in. Hg)the needle runs slightly above .
STICKING VALVES:5. When the needle (dotted) remains steady at a normal vacuum but occasionally flicks (sha
13 kPa (4 in. Hg)back about , one or more valves may be sticking.
BURNED OR WARPED VALVES:6. A regular, evenly-spaced, downscale flicking of the needle indicates one or
Insufficient hydraulic lash adjuster clearance will also cause this reaction.
POOR VALVE SEATING:
WORN VALVE GUIDES: 13 kPa (4 in. Hg)7. A small but regular downscale flicking can mean one or more valv
could be worn. As engine speed increases, the needle will become steady if the guides are responsible.
WEAK VALVE SPRINGS:9. When the needle oscillation becomes more violent as engine rpm is increased, weak
reading at idle could be relatively steady.
LATE VALVE TIMING:
IGNITION TIMING RETARDING:
INSUFFICIENT SPARK PLUG GAP:
INTAKE LEAK:
BLOWN HEAD GASKET:
RESTRICTED EXHAUST SYSTEM:10. A steady but low reading could be caused by late valve timing.11. Retar
the back pressure caused by a clogged muffler, kinked tail pipe or other concerns will cause the needle to slowly
When vacuum leaks are indicated, search out and correct the condition. Excess air leaking into the system will upset th
> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal
Intake Manifold: Service and RepairRemoval
1. Disconnect battery ground cable.2. Drain engine cooling system and remove the fan motor.3. Remove air cleaner o
Gasoline Engine
8. Disconnect fuel charging wiring from crankshaft position sensor (CKP sensor) and A/C clutch.9. Remove oil bypa
10. Disconnect fuel charging wiring from oil pressure sensor, oil filter adapter bracket and power steering pump and m
the way.
11. Disconnect EGR valve to exhaust manifold tube from RH exhaust manifold.12. Disconnect EGR back pressure tra
> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2708

13. Disconnect fuel charging
sensor), ignition coils andwiring from heated oxygen sensors (HO2S).14. Lower vehicle.15. Disconnect all ignitio
fuel injectors.
27. Remove fuel charging wiring retainers from valve cover stud bolts.28. Remove fuel charging wiring and transmiss
Accelerator Cable
30. Remove two bolts and intake manifold shield.31. Disconnect main emission vacuum control connector from fuel i
NOTE: The fuel charging wiring, fuel injection supply manifold and fuel injector nozzle tip can remain attached to the
37. Remove intake manifold gaskets.

Intake Manifold: Service and RepairInstallation

1. Clean sealing surfaces of intake manifold and cylinder heads.
NOTE: If a new intake manifold is being installed, transfer all necessary components onto new intake manifold.
2. Position new intake manifold gaskets on cylinder heads.3. Position intake manifold on cylinder heads.4. Install an
NOTE: Make sure alignment tabs on intake manifold gasket are aligned with holes in cylinder heads.
4.5-7 Nm (40-61 inch lbs.).

8-12 Nm (71-106 inch lbs.).
20-30 Nm (15-22 ft. lbs.).5. Install eight ignition coils and tighten the bolts to 6. Install the fuel injectors and fuel ra
Installation Sequence - Gasoline Engine
20-30 Nm (15-22 ft. lbs.).8. Tighten the nine bolts in the sequence shown to
NOTE: Upper crash bracket bolt is number six intake bolt and should only be hand-tightened.
20-309. Replace O-ring seal on water hose connection. Position water hose connection and upper radiator hose and i
Nm (15-22 ft. lbs.).
8-12 Nm (71-106 inch lbs.).

8-12 Nm (71-106 inch lbs.).
10. Install new throttle body adapter gasket.11. Install throttle body adapter. Tighten five retaining bolts to 12. Install
NOTE: Hand-tighten EGR-valve-to-exhaust manifold-tube fitting. Final tightening will be done later in procedure.
8-12 Nm (71-106 inch lbs.).

20-30 Nm (15-22 ft. lbs.).
8-12 Nm (71-106 inch lbs.).
7-9 Nm (62-80 inch lbs.).

14. Connect main emission vacuum control connector to fuel pressure regulator and evaporative emission valve.15. In

35-45 Nm (26-33 ft. lbs.).
35-45 Nm (26-33 ft. lbs.).
30. Connect fuel charging wiring to ignition coils, fuel injectors and camshaft position sensor.31. Raise vehicle on hoi
> Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > With Convention
The90
magnetic
degreeItgauge
consists
has of
thetwo
following
primaryfeatures:-
coils, one of which is wound at a angle to the other one.
Oil Pressure Switch

Theisoil
threaded
switch:-
> Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > With Convention
Theoil
oilpressure
indication engine.

Oil Pressure Switch
> Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Specifications
Crankshaft Main Bearing Seal: Specifications

Crankshaft Rear Oil Seal Retainer Bolts ..........................................................................................................................
> Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Specifications > Page 2721
Crankshaft Main Bearing Seal: Service and Repair

REMOVAL
1. Remove transmission from vehicle.2. Remove flywheel.3. Remove crankshaft oil slinger using Rear Crankshaft S
CAUTION: Use care to avoid damaging retainer when removing seal or engine oil leakage may occur upon reas
4. Remove crankshaft rear oil seal using Rear Crankshaft Seal Remover 303-519 and Slide Hammer 100-001.5. If re
INSTALLATION
1. Clean and inspect crankshaft rear oil seal retainer and retainer-to-cylinder block mating surfaces.
NOTE:
2. Apply a 2.0 mm (0.08 inch) continuous bead of Sealant 509 or equivalent meeting Ford specification WSK-M2G3
shown.
NOTE: Crankshaft rear oil seal retainer must be installed and bolts tightened to specification within five minute
Rear Oil Seal Retainer Tightening Sequence
8-12 Nm (71-106 inch lbs.).
3. Install crankshaft rear oil seal retainer and tighten bolts in sequence shown to 4. Install new crankshaft rear oil sea
> Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine Head Gasket - Approved Re
Engine Head Gasket - Approved Replacement Procedures
Article No.02-1-4
01/21/02
ENGINE - APPROVED HEAD GASKET REPLACEMENT SERVICE PROCEDURES
FORD:1992-1997 THUNDERBIRD1992-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS1995-2000 C
LINCOLN:1992-2002 CONTINENTAL, TOWN CAR2000-2002 LS1998-2002 NAVIGATOR2002 BLACKWOOD
MERCURY:1992-1997 COUGAR1992-1999 TRACER1992-2002 GRAND MARQUIS, SABLE1995-2000 MYSTIQ
ISSUESome engine assemblies with aluminum cylinder heads repaired in-vehicle have been found to leak coolant and/
ACTIONRefer to the following Service Information for recommended gasket sealing surface preparation procedures. I
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
OASIS CODES: 401000, 402000, 403000, 499000

Aluminum Cylinder Head - Removal From Engine
> Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine Head Gasket
- Approved Replacement Procedures > Page 2726

WARNING
ALUMINUM CYLINDER HEADS ARE HIGHLY POLISHED AND MUST BE HANDLED WITH EXTREME C
NOTE
SOME ENGINES REQUIRE A "DE-TORQUING" PROCEDURE OF THE CYLINDER HEAD BOLTS. CONSU
NOTE
IN SOME ENGINE APPLICATIONS, IT MAY BE NECESSARY TO "RUBBER BAND" A FEW OF THE HEA
Place CLEAN shop towels over the cylinder block bores to prevent further contamination from reaching internal parts
Gasket surfaces are machined to near-mirror surface quality. Scratches, dents, gouges, and other impressions may allow
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 "w
Ensure that the mating cylinder block surface is completely free of solid contamination, corrosion, and fluids. Use Mot
WARNING
UNDER NO CIRCUMSTANCES ARE ANY ALUMINUM GASKET SURFACES TO BE CLEANED USING RA
The original head bolts are to be discarded. Only new head bolts are acceptable for use in a head gasket repair. Use of o
The corresponding
head must not contain
bolt holes
anyinimpressions
the cylinderon
block
its sealing
must besurface
free ofdeeper
contamination
than 0.001"
consisting
(0.025 mm).
of dirtThere
particles,
mustcoolant,
not be an
an
To clean the cylinder block gasket surface, a plastic or wood scraper in combination with Motorcraft Metal Surface Cle
It is not necessary to expect aluminum head surfaces to be shiny and bright after the vehicle has been in service. Sandin
> Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine Head Gasket
- Approved Replacement Procedures > Page 2727

Machining of aluminum heads and blocks is an unacceptable field practice for quality control purposes of flatness and
Installation Onto the Cylinder Block Surface
WARNING
ANY GASKET SEALING AIDS WHICH ARE NOT LIMITED TO, AND INCLUDE AVIATION CEMENT, CO
Ensure that all surfaces of the cylinder block, cylinder head, and gasket are fully free of any solid or liquid contaminati
Using Workshop Manual procedures, assemble the head to the block carefully. Do not allow the gasket surfaces to scra
Do not use "cheater pipes" on torque wrenches. Use a known quality, calibrated torque wrench. Pull evenly and steady
Once the engine is fully reassembled, be sure that fluid levels have been topped off as required for the operation. When
WARNING
DO NOT RACE THE ENGINE UPON INITIAL STARTUP. MAINTAIN ENGINE IDLE TO BUILD OIL PRESS
Allow a warm up period, which brings the engine to normal operating temperature. Check for leaks around the gasket j
Shut down the engine, allow for a cool-down and drain-back period to enable fluids to return to levels. Check fluid leve
> Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair
Front Crankshaft Seal: Service and Repair

See: Tools and Equipment
REMOVAL
1. Disconnect battery ground cable. 2. Release drive belt tensioner and remove drive belt.3. Raise vehicle on hoist.4.
5. Install Crankshaft Damper Remover 303-009 on crankshaft pulley and pull crankshaft pulley from crankshaft.6. U
INSTALLATION
1. Lubricate seal bore in engine front cover and seal lip with clean Super Premium SAE 5W30 Motor Oil X0-5W30-
WSS-M2C153-G.
2. Using Crankshaft Seal Replacer / Cover Aligner 303-335, install crankshaft front seal.
3. Using Crankshaft Damper Replacer 303-102, install crankshaft pulley.

> Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 2731

4. Apply Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6
shown.
NOTE: Make sure key on crankshaft aligns with keyway of crankshaft pulley.
5. Install crankshaft pulley bolt and crankshaft pulley retaining washer.
90 Nm (66 ft. lbs.).
47-53 Nm (35-39 ft. lbs.). 85-95 degrees.Tighten the cylinder head in four steps:a. Tighten to b. Loosen one com
6. Lower vehicle.7. Install drive belt.8. Connect battery ground cable.9. Start engine and check for leaks.
> 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 detector to a cr
valve and intake valve opens. The spark plugs on the leaking cylinders will probably show deposits of burned oi
For additional diagnosis

> Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Testing and Inspection > Page 2735
Valve Guide Seal: Service and Repair

REMOVAL
1. Remove valve covers and rocker arms.2. Remove spark plug from applicable cylinder. 3. Position piston at top of
NOTE:
Failure of air pressure to hold the exhaust valve and intake valve closed while performing the following steps is a
4. Install an air line with an adapter in the spark plug hole and turn air supply ON.
7. Remove valve spring retainer keys, valve spring retainer and valve spring.
CAUTION:
If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve(s) t
8. Using locking pliers, remove valve stem seal.
9. Repeat Steps 2 through 8 until all necessary valve stem seals are removed.
INSTALLATION
1. Remove air pressure from spark plug adapter. Inspect the valve stem for damage. Rotate the valve and check the v
movement during rotation. Move the valve up and down through normal travel in the valve guide and check the s
CAUTION: Piston must be at top dead center (TDC) of cylinder being serviced.
2. If the condition of the valve is satisfactory, apply clean Super Premium SAE 5W30 Motor Oil XO-5W30-QSP me
> Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Testing and Inspection > Page 2736

WSS-M2C153-G to the valve stem and hold the valve closed.
CAUTION: If the valve has been damaged, it will be necessary to remove the cylinder head for service.
2. Apply the air pressure within the cylinder.
3. Install new valve stem seal using Valve Stem Seal Replacer 303-383.4. Position valve spring and valve spring reta
10. Install rocker arms and valve covers.11. Start engine and check for leaks.
> Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications

> Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 2741
Oil Pressure Switch

Theisoil
threaded
switch:-
> Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications
Camshaft Gear/Sprocket: Specifications

> Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications > Page 2746
Camshaft Gear/Sprocket: Testing and Inspection
Inspect the camshaft sprocket for warping or abnormal wear. Inspect the camshaft sprocket teeth for wear, deformation
> Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications > Page 2747
Camshaft Gear/Sprocket: Service and Repair
REMOVAL
NOTE:
INSTALLATION
NOTE:

> Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Testing and Inspection
Crankshaft Gear/Sprocket: Testing and Inspection
CAUTION: Handle crankshaft sprocket with care to avoid possible damage to the finished surfaces.
Inspect crankshaft sprocket for nicks, burrs or roughness that would cause premature wear. If crankshaft sprocket is w
> Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Testing and Inspection > Page 2751
Crankshaft Gear/Sprocket: Service and Repair

REMOVAL
NOTE:
INSTALLATION
NOTE:
> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Removal
Timing Chain: Service and RepairRemoval
REMOVAL
1. Remove valve covers and engine front cover.
CAUTION:
At no time, when the timing chain(s) are removed and the cylinder heads are installed, may the crankshaft and/or
NOTE:
Because this is not a free-wheeling engine, if it jumps time, there will be damage to the valves and/or pistons and
2. Remove crankshaft position sensor pulse wheel.
3. Rotate engine to No. 1 top dead center (TDC).

4. Install Cam Positioning Tool Adapters 303-413 and Cam Positioning Tool 303-380 on flats of camshaft at rear of
NOTE:
- This will prevent accidental rotation of the camshafts.
-
Cam Positioning Tool Adapters 303-413 and Cam Positioning Tool 303-380 must be installed on camshaf
> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Removal > Page 2756

5. Remove two bolts retaining RH timing chain tensioner to cylinder head and remove timing chain tensioner.
NOTE:
If tensioners are to be reused, they must first be compressed and a suitable tool (lock pin) inserted into them for
6. Remove RH timing chain tensioner arm.7. Remove two bolts retaining RH timing chain guide to cylinder head an
NOTE:
Cam Positioning Tool Adapters 303-413 and Cam Positioning Tool 303-380 must be installed on camshaft to pre
10. Remove LH timing chain tensioner arm.11. Remove two bolts retaining LH timing chain guide to cylinder head an
CAUTION: Do not rotate crankshaft and/or camshafts or possible engine damage may occur.
14. Inspect the plastic running face on timing chain tensioner arms and timing chain guides. If worn or damaged, remo
pump screen cover and tube.
Timing Chain: Service and RepairInstallation

INSTALLATION
8-12 Nm (71-106 inch lbs.).1. Install timing chain guides (both sides). Install timing chain guide retaining bolts. Tig
NOTE:
-
If engine has jumped time, make sure that all repairs to engine components and/or valve train have been m
-

2. If removed, position LH camshaft sprocket spacer and camshaft sprocket on camshaft.3. Install washer and camsh
6. If, removed, install LH crankshaft sprocket.
NOTE:
- Crankshaft sprockets are identical. They may only be installed one way. Refer to the illustration for prope
- Make sure tapered part of crankshaft sprocket faces away from cylinder block.
Timing Chain Marks
7. Install LH timing chain on camshaft sprocket. Make sure copper link of timing chain lines up with timing mark of
NOTE: If copper links of timing chain are not visible, split both timing chains in half and mark the two opposin
8. Install LH timing chain on crankshaft sprocket. Make sure copper link of timing chain lines up with timing mark o

Fig. 26 Crankshaft Sprocket Position
NOTE: Make sure tapered part of crankshaft sprocket faces toward cylinder block.
10. Install RH timing chain on camshaft sprocket. Make sure copper link of timing chain lines up with timing mark of

Fig. 25 Crankshaft To Camshaft Timing
20-30 Nm (15-22 ft. lbs.).11. Install RH timing chain on crankshaft sprocket. Make sure copper link of timing chain l
13. Install Crankshaft Holding Tool 303-448 over crankshaft and engine front cover alignment dowel to position cran

14. Lubricate timing chain tensioner arm contact surfaces with clean Super Premium SAE 5W30 Motor Oil XO-5W30
specification WSS-M2C153-G land install RH and LH timing chain tensioner arms on their dowels.
15. With a suitable C-clamp around the timing chain tensioner arm and timing chain guide, remove all slack from tim
to bend the timing chain guide.
16. Remove lock pins from timing chain tensioners and make sure all timing marks are aligned.

110-13017. Using Cam Positioning Tool Adapters 303-413 and Cam Positioning Tool 303-380 to align camshaft, tigh
Nm (82-95 ft. lbs.).
18. Install Tool-4201-C Dial Indicator with Bracketry or equivalent in cylinder 1 spark plug hole. Check that camshaf
intake valve at 114 degrees after top dead center (TDC).
NOTE: If not at maximum lift, loosen camshaft sprocket bolt and repeat Steps 12- 15.
19. Remove Cam Positioning Tool Adapters 303-413, Cam Positioning Tool 303-380 and Crankshaft Positioning Too
> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Specifications
Timing Chain Guide: Specifications

Timing Chain Guide Bolts ...............................................................................................................................................
> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Removal
Timing Chain Tensioner: Service and RepairRemoval

REMOVAL
1. Remove valve covers and engine front cover.
CAUTION:
At no time, when the timing chain(s) are removed and the cylinder heads are installed, may the crankshaft and/or
NOTE:
Because this is not a free-wheeling engine, and it jumps time, there will be damage to the valves and/or pistons an
2. Remove crankshaft position sensor pulse wheel.
3. Rotate engine to No. 1 top dead center (TDC).

4. Install Cam Positioning Tool Adapters 303-413 and Cam Positioning Tool 303-380 on flats of camshaft.
NOTE:
- This will prevent accidental rotation of the camshafts.
-
5. Remove two bolts retaining RH timing chain tensioner to cylinder head and remove timing chain tensioner.
NOTE: If tensioners are to be reused, they must first be compressed and a suitable tool (lock pin) inserted into th
> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Removal > Page 2770

compressed. This will aid in reassembly.
6. Remove RH timing chain tensioner arm.7. Remove two bolts retaining RH timing chain guide to cylinder head an
NOTE:
Cam Positioning Tool Adapters 303-413 and Cam Positioning Tool 303-380 must be installed on camshaft to pre
10. Remove LH timing chain tensioner arm.11. Remove two bolts retaining LH timing chain guide to cylinder head an
CAUTION: Do not rotate crankshaft and/or camshafts or possible engine damage may occur.
14. Inspect the plastic running face on timing chain tensioner arms and timing chain guides. If worn or damaged, remo
pump screen cover and tube.
Timing Chain Tensioner: Service and RepairInstallation

INSTALLATION
8-12 Nm (71-106 inch lbs.).1. Install timing chain guides (both sides). Install timing chain guide retaining bolts. Tig
NOTE:
-
If engine has jumped time, make sure that all repairs to engine components and/or valve train have been m
-
2. If removed, position LH camshaft sprocket spacer and camshaft sprocket on camshaft.3. Install washer and camsh
5. Install washer and camshaft sprocket retaining bolt. Do not tighten at this time.

6. If, removed, install LH crankshaft sprocket.
NOTE:
- Crankshaft sprockets are identical. They may only be installed one way. Refer to the illustration for prope
- Make sure tapered part of crankshaft sprocket faces away from cylinder block.
Timing Chain Marks
7. Install LH timing chain on camshaft sprocket. Make sure copper link of timing chain lines up with timing mark of
NOTE: If copper links of timing chain are not visible, split both timing chains in half and mark the two opposin
8. Install LH timing chain on crankshaft sprocket. Make sure copper link of timing chain lines up with timing mark o
NOTE: Make sure tapered part of crankshaft sprocket faces toward cylinder block.
10. Install RH timing chain on camshaft sprocket. Make sure copper link of timing chain lines up with timing mark of

Fig. 25 Crankshaft To Camshaft Timing
20-30 Nm (15-22 ft. lbs.).11. Install RH timing chain on crankshaft sprocket. Make sure copper link of timing chain l
13. Install Crankshaft Holding Tool 303-448 over crankshaft and engine front cover alignment dowel to position cran

14. Lubricate timing chain tensioner arm contact surfaces with clean Super Premium SAE 5W30 Motor Oil XO-5W30
specification WSS-M2C153-G land install RH and LH timing chain tensioner arms on their dowels.
15. With a suitable C-clamp around the timing chain tensioner arm and timing chain guide, remove all slack from tim
to bend the timing chain guide.
16. Remove lock pins from timing chain tensioners and make sure all timing marks are aligned.

110-13017. Using Cam Positioning Tool Adapters 303-413 and Cam Positioning Tool 303-380 to align camshaft, tigh
Nm (82-95 ft. lbs.).
18. Install Tool-4201-C Dial Indicator with Bracketry or equivalent in cylinder 1 spark plug hole. Check that camshaf
intake valve at 114 degrees after top dead center (TDC).
NOTE: If not at maximum lift, loosen camshaft sprocket bolt and repeat Steps 12- 15.
19. Remove Cam Positioning Tool Adapters 303-413, Cam Positioning Tool 303-380 and Crankshaft Positioning Too
> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications
Timing Cover: Specifications

Engine Front Cover Bolt ..................................................................................................................................................
> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Removal
Timing Cover: Service and RepairRemoval
CAUTION: 1. The valve covers must be removed prior to removing the engine front cover or engine damage and/o
reassembly.
2. Remove drive belt. 3. Remove water pump pulley.4. Raise vehicle on hoist. 5. Remove bolts retaining power steer
NOTE: The front lower bolt on the power steering pump will not come all the way out.
6. Wire power steering pump out of way.7. Remove four oil pan-to-engine front cover bolts.8. Remove crankshaft pu
9. Install Crankshaft Damper Remover 303-009 on crankshaft pulley and pull crankshaft pulley from crankshaft.
10. Lower vehicle.11. Remove nut retaining air conditioner high-pressure line to RH front cover stud.12. Remove bot
> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Removal > Page 2781

18. Remove eight stud bolts and seven bolts retaining engine front cover to engine.19. Remove engine front cover.
Timing Cover: Service and RepairInstallation

1. Remove all traces of dirt, oil or previously applied sealant from the engine front cover cylinder head, valve cover,
block sealing surfaces. Clean all sealing surfaces with Metal Surface Cleaner F4AZ-1 9A536-RA or equivalent. S
2. Replace crankshaft front seal and engine front cover gasket (three pieces).
3. Apply an 8-12 mm (0.32-0.47 inch) bead of Silicone Gasket and Sealant F6AZ-19562-AA or equivalent in locatio
4. Install engine front cover on engine.
CAUTION: Engine front cover must be rolled into position, do not slide engine front cover on oil pan gasket, or

20-30 Nm (15-22 ft. lbs.)5. Install studs and bolts retaining engine front cover to engine in location shown. Tighten t
NOTE: Engine front cover must be positioned and retaining bolts and stud bolts tightened to specification withi
8-12 Nm (71-106 inch lbs.).
6. Install crankshaft position sensor. Tighten bolt to 7. Attach the fuel charging wiring to the crankshaft position sens
20-30 Nm (15-22 ft. lbs.).

10. Position air conditioner high-pressure line on front cover retaining stud and install nut. Tighten to 11. Raise vehicl
of the keyway and crankshaft pulley.

13. Install four oil pan to engine front cover bolts.
20 Nm (15 ft. lbs.). 60 degrees.Tighten in two steps in sequence shown:a. Tighten to b. Tighten an additional
20-30 Nm (15-22 ft. lbs.).
20-30 Nm (15-22 ft. lbs.).

14. Position power steering pump on engine and install four retaining bolts. Tighten to 15. Lower vehicle.16. Install w
WSS-M2C153-G to the specified level.
19. Start engine and check for leaks.
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 2790

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 2791

REMOVAL
INSTALLATION
7.75 Nm (68 lb in)
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications

Hot Idle ................................................................................................................................................................................
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2795

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation

-
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation > P

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation > P
REMOVAL
INSTALLATION
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions
NOTE
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2806
Fuel Pressure Gauge
Special Tool(s)
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications
Firing Order 1-3-7-2-6-5-4-8
Coil On Plug
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap
Spark Plug Gap .................................................................................................................................................................. 1

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 2818
Spark Plug Gap .................................................................................................................................................................. 1

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2819

Spark Plug Type ...................................................................................................................................................................




REMOVAL
INSTALLATION
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Compression Test

TEST RESULTS
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Compression Test > Page 2829
Example Readings
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications

> Engine, Cooling and Exhaust > Engine > Water Pump > Drive Pulley, Water Pump > Component Information > Specifications
Drive Pulley: Specifications

Water Pump Pulley Bolt ...................................................................................................................................................
> Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations
Coolant: Technical Service BulletinsEngine Coolant - Propylene Glycol Recommendations
Article No.01-23-6
11/26/01
ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLA
ENGINE COOLANT - PROPYLENEGLYCOL-BASED - FORD MOTOR COMPANYPOSITION ON PROPYLE
LINCOLN:1989-1992 MARK VII1989-2002 CONTINENTAL, TOWN CAR1993-1998 MARK VIII2000-2002 LS19

MERCURY:1989-1994 TOPAZ1989-1997 COUGAR1989-2002 GRAND MARQUIS, SABLE1991-1994 CAPRI199
MERKUR:1989 SCORPIO, XR4TI
This article is being republished in its entirety to update the model year coverage.
ISSUEThis TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolant
ACTION
> Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations
> Page 2842

Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford
Published information suggests that engine coolants made with propylene glycol may provide engine cooling performa
Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be m
Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engin

> Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications
Coolant: Capacity Specifications

13.3 L (14.1 U.S. quarts)Cooling System Refill Capacities ...........................................................................................
> Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2845
Coolant: Fluid Type Specifications

COOLANT TYPE
...............................................................................................................................................................
Coolant Mixture with Water................................................................................................................................................
Warning: Do not mix coolant types. Check the owners manual or refer to your local dealer for the correct coolan
> Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Coolant: Initial Inspection and Diagnostic Overview

Check engine coolant level in the degas bottle at least once a month.
With a cold engine, the engine coolant level must be maintained at or above the COLD FILL LEVEL mark.
At normal engine operating temperature, the engine coolant level should be above the COLD FILL LEVEL mark
If no engine coolant is observed in the degas bottle or when a coolant level change does not occur, check the syst
1. With the engine cold, remove the pressure relief cap and inspect the filler neck sealing gasket for foreign material.
Cleaning and Inspection. Rinse pressure relief cap in clean water.
The pressure relief cap used on this system is unique. Replace only with the proper pressure relief cap.
2. Replenish the engine coolant in the degas bottle and add coolant to degas bottle as required.3. Install the pressure r
A low engine coolant level in the radiator can cause poor heater and defroster performance. If this condition exist
Engine Coolant F6AZ-19544-AA (orange), or equivalent and water, fill degas bottle to indicated level and rep
c. Start the engine and run until the water thermostat opens.d. Observe the level of engine coolant in the degas bo
level by adding a 50/50 mixture of Ford Premium Cooling System Fluid E2FZ-19549-AA (green), Ford Exten
e. Check for leakage at the following locations:
- all hoses and hose connections
- radiator seams, radiator core and radiator draincock
- all cylinder block core plugs and drain plugs
- edges of all cooling system gaskets
- transmission fluid cooler fittings
- vehicle heating system components
- water pump
f. Examine oil level dipstick for evidence of engine coolant in engine oil.
g. Check radiator for evidence of oil in coolant. Install cooling system analyzer to assist in testing the cooling sys
recommended connections and testing procedures.
> Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2848
Coolant: Component Tests and General Diagnostics

1. Check engine coolant for dirty or rusty appearance. Dirty or rusty coolant requires replacement to protect the cooli
damage. Replace the coolant.
NOTE: Use only a permanent-type coolant such as Ford Premium Cooling System Fluid E2FZ-19549-AA or eq
2. If coolant condition is satisfactory, check coolant concentration for proper protection level. Use a Rotunda Battery
or equivalent hydrometer for testing. Maintain a protection level of at least -30 C (-20 F) to preserve anti-rust cor
If concentration level is low, partially drain the cooling system by opening the radiator draincock or by partially r
> Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation
Coolant Reservoir: Description and Operation

NOTE: When the water thermostat is closed there is no flow through the degas system.
The degas system operates in the following manner:-

This is
Trapped airdone bycooling
in the a pressurized
systemreservoir system which continuously separates the air from the cooling syste
must be removed.-
- When the water thermostat is open, engine coolant flows through a small hose from the top of the radiator out
- The degas bottle separates any entrapped air from the coolant and replenishes the system through its outlet to
-
The degas bottle serves as the location for service fill, coolant expansion during warm up, system pressurizati
- The degas bottle is designed to have approximately 0.5 to 1 liter (0.53- 1.06 qts) of air when cold to allow for
> Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation > Page 2852
Coolant Reservoir: Service and Repair

REMOVAL
CAUTION:
1. Drain radiator until engine coolant is out of degas bottle. Disconnect radiator to degas bottle hose at degas bottle.2
INSTALLATION
6-7 Nm (54-62 inch lbs.).
1. Position degas bottle in vehicle and install retaining nuts. Tighten retaining nuts to 2. Connect lower radiator hose
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Inter
Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating
Article No.00-10-3
05/15/00

DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins >
Customer Interest for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 2862

Service Procedure
4. Select PCM.
NOTE:
14.

Customer Interest for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 2863

24. Select TRIGGER.
26. Select YES.

> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical S
Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating
Article No.00-10-3
05/15/00

DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100
All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 2869

Service Procedure
4. Select PCM.
NOTE:
14.

All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 2870

24. Select TRIGGER.
26. Select YES.

> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Technical Service Bulletins > Customer Interest: > 00-
Spark Knock While Accelerating
Article No.00-10-3
05/15/00

DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Technical Service Bulletins > Customer
Interest: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 2879

Service Procedure
4. Select PCM.
NOTE:
14.

> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Technical Service Bulletins > Customer
Interest: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 2880

24. Select TRIGGER.
26. Select YES.

> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Technical Service Bulletins > All Technical Service Bu
Motor: > 03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure
Cooling System - Cooling Fan Motor Service Procedure
Article No.03-2-6
03/02/03
^ ELECTRICAL - REVISED COOLING FAN MOTOR AVAILABLE
^ COOLING - REVISED COOLING FAN MOTOR AVAILABLE
Article 03-1-1 is being republished in its entirety to update the artwork figures.
ISSUEWhen necessary to service the cooling tan assembly motor, service 1998-2000 model with later model cooling f
ACTIONUse cooling fan assembly 1W7Z-8C607-AA to service Crown Victoria/Grand Marquis vehicles built 1998 Jo
Parts Block
OTHER APPLICABLE ARTICLES: 01-10-12SUPERSEDES:03-1-1WARRANTY STATUS: Eligible Under The Pro

030206A Replace Engine Cooling 0.9 Hr.
Fan And Install NewWiring Connector
DEALER CODING
CONDITION
BASIC PART NO. CODE
8C607 42
OASIS CODES: 402000

Disclaimer
Service Procedure
For 1998 - 2000 Model Year Vehicles Built Before April 4, 2000
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Radiator Cooling Fan Motor: > 03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure > Page 2886

2. Disconnect fan motor electrical connector.
3. Position lower radiator hose off support bracket and remove wire harness pushpin from fan shroud.
4. Remove the bolt and position aside degas bottle.
NOTE
THE REMOVAL AND INSTALLATION OF THE FAN AND SHROUD ASSEMBLY WILL REQUIRE A SECO
5. Remove (2) bolts and remove fan and shroud assembly.
6. Install lower radiator hose support bracket onto new fan shroud.
7. Install new fan and shroud. Torque to 43.6 Lb-in (5.7 N.m).
8. Reposition the degas bottle and install bolt. Torque to 61.2 - 91.8 Lb-in (8-12 N.m).
9. Remove enough tape from the wire harness starting at fan connector to install fan connector pig tail, then remove
10.
Cut the existing connector from the engine compartment wiring harness make each cut an inch and a half from th
11. Splice the three wires in the pigtail to the engine compartment harness as follows:
a. Remove 0.75" (19 mm) of insulation from the wires to be spliced (Figure 1).
b. Insert a 2" (50 mm) length of dual wall heat shrink tubing containing hot melt wax on the wire.

c. Splay the strands of the cut wires (Figure 2).
d. Twist/mesh the strands of the two wires together (Figure 3).


e. Wrap a 4-5" (100-125 mm) strand of wire tightly around the meshed ends (Figure 4).
f. Repeat previous step.
g.
Solder the tightly wrapped meshed wires (Figure 5). Ensure the splice is thoroughly heated and solder flow

h. Center the heat shrink tubing on the splice (Figure 6).
i. Heat the entire length of the heat shrink tubing until the hot melt wax appears from both ends of the tubing
12. Install and tape spliced wires back into convolute.


13.
Connect fan motor, position back tower hose onto support bracket, and install wire harness pushpin onto new fan
14. Connect battery ground cable. Torque to 68.5 Lb-in (9 N.m).
15. Verify fan operation with NGS/WDS.

> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Technical Service Bulletins > All Technical Service Bu
Motor: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating
Article No.00-10-3
05/15/00

DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100
Technical Service Bulletins for Radiator Cooling Fan Motor: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 2895

Service Procedure
4. Select PCM.
NOTE:
14.

Technical Service Bulletins for Radiator Cooling Fan Motor: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 2896

24. Select TRIGGER.
26. Select YES.

> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Technical Service Bulletins > All Other Service Bulleti
03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure
Cooling System - Cooling Fan Motor Service Procedure
Article No.03-2-6
03/02/03
^ ELECTRICAL - REVISED COOLING FAN MOTOR AVAILABLE
^ COOLING - REVISED COOLING FAN MOTOR AVAILABLE
Article 03-1-1 is being republished in its entirety to update the artwork figures.
ISSUEWhen necessary to service the cooling tan assembly motor, service 1998-2000 model with later model cooling f
ACTIONUse cooling fan assembly 1W7Z-8C607-AA to service Crown Victoria/Grand Marquis vehicles built 1998 Jo
Parts Block
OTHER APPLICABLE ARTICLES: 01-10-12SUPERSEDES:03-1-1WARRANTY STATUS: Eligible Under The Pro

030206A Replace Engine Cooling 0.9 Hr.
Fan And Install NewWiring Connector
DEALER CODING
CONDITION
BASIC PART NO. CODE
8C607 42
OASIS CODES: 402000

Disclaimer
Service Procedure
For 1998 - 2000 Model Year Vehicles Built Before April 4, 2000
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Radiator Cooling Fan Motor: > 03-2-6 > Feb > 03 > Cooling System - Cooling Fan Motor Service Procedure > Page 2902

2. Disconnect fan motor electrical connector.
3. Position lower radiator hose off support bracket and remove wire harness pushpin from fan shroud.
4. Remove the bolt and position aside degas bottle.
NOTE
THE REMOVAL AND INSTALLATION OF THE FAN AND SHROUD ASSEMBLY WILL REQUIRE A SECO
5. Remove (2) bolts and remove fan and shroud assembly.
6. Install lower radiator hose support bracket onto new fan shroud.
7. Install new fan and shroud. Torque to 43.6 Lb-in (5.7 N.m).
8. Reposition the degas bottle and install bolt. Torque to 61.2 - 91.8 Lb-in (8-12 N.m).
9. Remove enough tape from the wire harness starting at fan connector to install fan connector pig tail, then remove
10.
Cut the existing connector from the engine compartment wiring harness make each cut an inch and a half from th
11. Splice the three wires in the pigtail to the engine compartment harness as follows:
a. Remove 0.75" (19 mm) of insulation from the wires to be spliced (Figure 1).
b. Insert a 2" (50 mm) length of dual wall heat shrink tubing containing hot melt wax on the wire.

c. Splay the strands of the cut wires (Figure 2).
d. Twist/mesh the strands of the two wires together (Figure 3).


e. Wrap a 4-5" (100-125 mm) strand of wire tightly around the meshed ends (Figure 4).
f. Repeat previous step.
g.
Solder the tightly wrapped meshed wires (Figure 5). Ensure the splice is thoroughly heated and solder flow

h. Center the heat shrink tubing on the splice (Figure 6).
i. Heat the entire length of the heat shrink tubing until the hot melt wax appears from both ends of the tubing
12. Install and tape spliced wires back into convolute.


13.
Connect fan motor, position back tower hose onto support bracket, and install wire harness pushpin onto new fan
14. Connect battery ground cable. Torque to 68.5 Lb-in (9 N.m).
15. Verify fan operation with NGS/WDS.

> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions
Radiator Cooling Fan Motor: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Pa
Cooling Fan
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 2917
Radiator Cooling Fan Motor: Description and Operation
TheThe system
cooling fanconsists of a fan blade
system functions and a single speed cooling fan motor located behind the radiator.
as follows:-
-
The cooling fan motor is wired to operate only when the ignition switch is in the RUN position and prevents t
- The electric drive fan has normal start/stop noise levels.
Radiator Cooling Fan Motor: Testing and Inspection
Radiator Cooling Fan Motor: Service and Repair

REMOVAL
CAUTION:
1. Disconnect (pull apart) the cooling fan motor wiring connector at the side of the fan shroud.2. Remove fan shroud
INSTALLATION
3-6 Nm (27-53 inch lbs.).

3-5 Nm (27-44 inch lbs.). 50-62 Nm (37-45 ft. lbs.).1. Follow removal procedure in reverse order.2. Tighten cooling
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations

Engine View
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 2923

> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 2924

Cooling Fan
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instruction

- System Diagrams
- Grounds Diagrams
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 2927


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instruction
Cooling Fan
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 2935
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Locations

Engine View
NOTE:
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Locations > Page 2939

NOTE:
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Testing and Inspection
Fan Blade: Testing and Inspection

Check fan blade for cracks or damage. Replace.
WARNING: DO NOT ATTEMPT TO STRAIGHTEN OR SERVICE A FAN BLADE. REPLACE FAN BLAD
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Testing and Inspection > Page 2943
Fan Blade: Service and Repair

REMOVAL
CAUTION:
WARNING: DO NOT ATTEMPT TO STRAIGHTEN OR SERVICE FAN BLADE. REPLACE FAN BLADE I
1. Disconnect (pull apart) the cooling fan motor wiring connector at the side of the fan shroud.2. Remove fan shroud
INSTALLATION
3-6 Nm (27-53 inch lbs.).

3-5 Nm (27-44 inch lbs.). 50-62 Nm (37-45 ft. lbs.).1. Follow removal procedure in reverse order.2. Tighten cooling
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Maximum Speed Fan Clutch Requirement Test
Fan Clutch: Testing and InspectionMaximum Speed Fan Clutch Requirement Test
1. If the Minimum Speed Fan Clutch Requirement Test was not performed, follow Steps 1 through 5 under Minimum
Test.
Disconnect the electric fan.
2. Block off areas on each side of the radiator with two strips of cardboard 254 x 508 mm (10 x 22 in) inserted vertic
A/C condenser core. This will raise the temperature of the air striking the fan clutch and should cause the fan blad
NOTE: The engine coolant temperature should be above 87 C (189 F) for maximum fan speed.
3. Place the air conditioning selector in the MAXIMUM position and the blower switch in the HIGH position.4. Adju
Specifications.
WARNING: TO AVOID THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE TO THE VEHIC
6. Synchronize the strobe light with the fan blade-to-fan clutch retaining bolt.7. The fan blade speed must meet or ex
10. Remove the tachometer, strobe light and throttle adjusting tool.
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Maximum Speed Fan Clutch Requirement Test
Fan Clutch: Testing and InspectionMinimum Speed Fan Clutch Requirement Test
NOTE:
- The auxiliary electric-drive fan must be disconnected prior to testing the fan clutch.
-
The fan clutch may stall when the auxiliary electric-drive fan is in operation. This is normal operation and may ca
1. Using a suitable marker, mark the water pump pulley, one of the fan blade retaining bolts and the crankshaft pulle
NOTE:
It may be necessary, in cold temperatures, to block the radiator with two strips of cardboard 254 x 508 mm (10 x
5. Start the engine and run it at approximately 1500 rpm until engine temperature has normalized.
6. Adjust the engine to the specified engine testing speed.7. Operate the strobe light at 3000 rpm and aim it at the wa
marks are synchronized.
8. Aim the strobe light at the fan blade retaining bolts. Adjust the strobe light until it is synchronized with the marked
blade appears to stand still).
9. The fan blade speed must not be greater than the specified fan blade test speed at 3000 water pump rpm.
10. Turn the engine off.11. If the fan blade speed was greater than the specified fan blade test speed, replace the fan cl
If the parts are not the correct ones, replace the parts and perform the test again.
12. If Maximum Speed Fan Clutch Requirement Test is going to be performed, do not remove the tachometer, strobe
Otherwise, remove the tachometer, strobe light and throttle adjusting tool.
> Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifi

ECT Sensor ..........................................................................................................................................................................

Engine View
> Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 2954

Engine View
> Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component

Engine View

ECT
NOTE:
ECT
> Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Location

Engine View
NOTE:
> Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Location

NOTE:
> Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Description and Operation > W
> Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Description and Operation > W
Page 2966


ThisHgauge
-
13,000 ohms 200 ohms 13,000 ohms
-
Diagnostic Bars
200 ohms
When the
Diagnostic topontwo
bars thisand bottom
gauge two bars
coolant gauge,
temperature a short
sender circuit
is lower thanmay
thebe
o
Fail Safe Cooling
(124C)
Allthe
Once eight
is met:-
(166C)
Allthe
is met:-
is mounted
sender:-
-
> Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair
Fan Shroud: Service and Repair

REMOVAL
CAUTION:
1. Turn the lower fan shroud in the upper fan shroud to allow clearance for removal of fan shroud.
2. Disconnect (pull apart) the electric cooling fan motor wiring connector at the RH side of the fan shroud.3. Remove
Fan Shroud
INSTALLATION
3-6 Nm (27-53 inch lbs.).

3-5 Nm (27-44 inch lbs.).
1. If removed, install electric cooling fan motor and fan blade onto fan shroud. Tighten retaining screws to 2. Install t
> 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: Customer InterestA/C - Heater Core Electrolysis/Leakage

TSB 06-21-19
10/30/06

SERVICE PROCEDURE
> 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 2978

b.
NOTE

> Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 >

o.
NOTE
CAUTION
NOTE
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
> Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oc
Electrolysis/Leakage
Heater Core: All Technical Service BulletinsA/C - Heater Core Electrolysis/Leakage

TSB 06-21-19
10/30/06

SERVICE PROCEDURE
> 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 2985

b.
NOTE

> Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: >

o.
NOTE
CAUTION
NOTE
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
> Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2987
Heater Core: Testing and Inspection
WARNING: CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSAR
The heater core is an all-aluminum core which has two rows of flat tubes to maximize engine coolant flow. It is located
1. Inspect for visible evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak
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 should not have bee
2. Check the system for loose or overtightened heater water hose clamps. The clamps should be tightened to 1.7-2.4
can cause leakage at the heater water hose connection and damage the heater core tube.
PLUGGED HEATER CORE
Check to see that the engine coolant is at the proper level. Start the engine and turn on the heater. When the engine coo

PRESSURE TEST
Use Rotunda Radiator Pressure Tester 014-R1072 or equivalent to perform pressure test.
1. Drain the coolant from the cooling system.
NOTE: Due to space limitations, a bench test may be necessary for pressure testing.
101 mm (4 inches)2. Disconnect the heater water hoses from the heater core tubes.3. Install a short piece of heater w
4. Fill the heaterorcore
014-R1072 and heater
equivalent water
in the hoses
heater with
water water
hose andSecure
ends. installthe
Plug BT-7422-B
heater and adapter
water hoses, BT-7422-A
plug and from
adapter with R
hose
241 kPa (35 psi)

three minutes
5. Attach the pump and gauge assembly from Rotunda Radiator Pressure Tester 014-R1072 or equivalent to the adap
core from the vehicle and perform bench test.

BENCH TEST
Use Rotunda Radiator Pressure Tester 014-R1072 or equivalent to perform bench test.
101 mm (4 inch)1. Drain all coolant from the heater core.2. Remove heater core from A/C evaporator housing.3. Co
014-R1072 or equivalent to the adapter.
241 kPa (35 psi)
4. Apply of air pressure to the heater core. Submerge the heater core in water.5. If a leak is observed, service or repl
> Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core
Heater Core: Service and RepairBack Flushing-Heater Core

CAUTION: The heater core must be back-flushed separately from the engine cooling system for proper back-flush wa
All engine cooling system flushing and back-flushing procedures must include a separate back-flushing of the heater co
The correct heater core back-flushing procedure is as follows:
1. Disconnect the heater core outlet heater water hose from the return fitting and install a female garden hose-end fitt
outlet heater water hose. Secure with a hose clamp.
2. Connect the female end of the outlet heater water hose to the male end of a water supply garden hose.3. Disconnec
tubes. Allow full water pressure to flow for approximately five minutes.
6. If a water valve is installed in the heater core inlet heater water hose, apply vacuum to the water valve vacuum mo
operation of the water valve and proper closure with no water leakage. Replace the water valve if required.
7. Remove the hose clamp and female garden hose-end adapter from the end of the outlet heater water hose and reco
hose onto the water pump fitting and heater return fitting.
8. Connect the inlet heater water hose onto the cylinder block fitting and intake manifold fitting.9. Fill the engine coo
Engine Coolant F6AZ-19544-AA (orange), or equivalent and water.
10. Test the system for proper heater performance with the specified engine cooling system conditions.
> Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 2992
Heater Core: Service and RepairRemoval and Installation
REMOVAL
1. Remove the heater air plenum chamber assembly. See: Heating and Air Conditioning/Heater Air Plenum Chambe
INSTALLATION
1. Carefully install heater core assembly into the heater air plenum chamber assembly. Visually check to make sure h
positioned.
2. Position the heater core cover and install the four retaining screws.3. Install the heater air plenum chamber assemb
> 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

TSB 06-21-19
10/30/06

SERVICE PROCEDURE
> Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 >

b.
NOTE

> Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 >

o.
NOTE
CAUTION
NOTE
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
> Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > O
Electrolysis/Leakage

TSB 06-21-19
10/30/06

SERVICE PROCEDURE
> Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: >

b.
NOTE

> Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: >

o.
NOTE
CAUTION
NOTE
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
> Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 3010

> Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 3011
REMOVAL
INSTALLATION
hoses.
> Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation > With Convention
Temperature Gauge: Description and OperationWith Conventional Instrument Cluster

The engine coolant temperature indication system is a magnetic type system that consists of:
- Engine Coolant Temperature Gauge (located in instrument cluster).
- Engine coolant temperature sender (located in intake manifold).
- necessary circuitry.
Engine Coolant Temperature Gauge

The90 degreeIt consists
instrument of threeCoolant
cluster Engine primaryTemperature
coils of wireGauge
calledhas
thethe
bobbin. One coil
following is wound at a angle to the othe
features:-
-
When power is applied, current flowing through the bobbin and sending unit forms a magnetic field which va
- The bobbin/coil assembly is pressed into a metal housing which has two holes for dial mounting.
- A permanent magnet, to which a shaft and pointer are attached, rotates to align at this primary field, resulting
- The gauge pointer remains in position when the ignition switch is turned to OFF.
- The gauge pointer moves to the correct position whenever the ignition switch is turned to RUN.
- An instrument voltage regulator, as used on previous models, is not used.
- The Engine Coolant Temperature Gauge is located in the lower RH portion of the instrument cluster.
> Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation > With Convention
Temperature Gauge: Description and OperationWith Electronic Instrument Cluster


ThisHgauge
-
13,000 ohms 200 ohms 13,000 ohms
-
Diagnostic Bars
200 ohms
When the
Diagnostic topontwo
bars thisand bottom
gauge two bars
coolant gauge,
temperature a short
sender circuit
is lower thanmay
thebe
o
Fail Safe Cooling
(124C)
Allthe
Once eight
is met:-
(166C)
Allthe
is met:-
is mounted
sender:-
-
> Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation > Page 3018
Temperature Gauge: Service and Repair

REMOVAL
NOTE: The oil pressure gauge is serviceable as part of the Engine Coolant Temperature Gauge.
1. Disconnect battery ground cable.2. Remove instrument cluster.3. Remove screws retaining instrument cluster main
INSTALLATION
1. Position gauge terminals to clips on instrument cluster back plate and press Engine Coolant Temperature Gauge in
> Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair
Radiator Drain Plug: Service and Repair
REMOVAL
CAUTION:
1. Turn the radiator draincock counterclockwise to unscrew. When the radiator draincock is unscrewed to the end of
draincock partially out from the radiator inlet tank.
2. Remove the radiator draincock from the radiator by squeezing the sides together with a pair of needle nose pliers.
from the radiator.
INSTALLATION
1 Nm (8 inch lbs.).1. Make sure O-ring is in groove on stem of radiator draincock.2. Water-saturate radiator drainco
> Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications
Radiator Cap: Specifications

Relief Cap Pressure ............................................................................................................................. 110 kPa (16 psi)
> Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications > Page 3026
Radiator Cap: Testing and Inspection
1. Inspect the areas under the vacuum valve and rubber seal for rust or dirt particles.2. Using warm tap water, raise th
wipe the sealing surface to remove any dirt particles.
> Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Testing and Inspection
Radiator Hose: Testing and Inspection
1. Inspect cooling system hoses and clamped hose connections for leaks or excessive deterioration. Service or replac
> Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower)
Radiator Hose: Service and RepairRadiator Hoses (Lower)

REMOVAL
1. Raise vehicle on hoist.2. Drain cooling system.3. Disconnect degas bottle return hose from degas bottle.
4. Remove three rear screws retaining lower splash shield to radiator support.5. Compress clamp tangs and remove lo
INSTALLATION
1. Position the clamps (clipless pop clamps are glued to hose) at least 5 mm (0.196 inch) from each end of hose. Coa
approved water-resistant sealer.
CAUTION: Make sure the clamps are beyond the bead and placed in the center of the clamping surface of the c
2. Compress clamp tangs and install lower radiator hose on water pump.3. Compress clamp tangs and install lower ra
> Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower) > Page 3032
Radiator Hose: Service and RepairRadiator Hoses (Upper)

REMOVAL
CAUTION:
1. Remove battery.2. Drain cooling system. 3. Compress clamp tangs and disconnect upper radiator hose from radiat
INSTALLATION
CAUTION: Make sure the clamps are beyond the radiator tank connector bead and placed in the center of the clam
1. Position the clamps (clipless pop clamps are glued to hose) at least 5.0 mm (0.195 inch) from each end of the hose
an approved water-resistant sealer.
2. Compress clamp tangs and install upper radiator hose onto thermostat cover connection.3. Compress clamp tangs
> Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins
Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating
Article No.00-10-3
05/15/00

DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100
> Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical
Service Bulletins > Customer Interest for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 3042

Service Procedure
4. Select PCM.
NOTE:
14.

Service Bulletins > Customer Interest for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 3043

24. Select TRIGGER.
26. Select YES.

> Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins
Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating
Article No.00-10-3
05/15/00

DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100
Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating >
Page 3049

Service Procedure
4. Select PCM.
NOTE:
14.

Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating >
Page 3050

24. Select TRIGGER.
26. Select YES.

> Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations

Engine View
> Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page
3054

> Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page
3055

Cooling Fan
> Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Informatio

- System Diagrams
- Grounds Diagrams
> Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams >


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Informatio
Cooling Fan
> Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 3066
> Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Com
Specifications

ECT Sensor ..........................................................................................................................................................................

Engine View
> Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/
Switch (For Computer) > Component Information > Specifications > Page 3073

Engine View
> Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/
Switch (For Computer) > Component Information > Specifications > Page 3074

Engine View

ECT
NOTE:
ECT
> Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Sw
Locations

Engine View
NOTE:
> Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Sw

NOTE:
> Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Inf
> With Conventional Instrument Cluster
> Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Inf
> With Conventional Instrument Cluster > Page 3085


ThisHgauge
-
13,000 ohms 200 ohms 13,000 ohms
-
Diagnostic Bars
200 ohms
When the
Diagnostic topontwo
bars thisand bottom
gauge two bars
coolant gauge,
temperature a short
sender circuit
is lower thanmay
thebe
o
Fail Safe Cooling
(124C)
Allthe
Once eight
is met:-
(166C)
Allthe
is met:-
is mounted
sender:-
-
> Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation > With Conventional Instrument Cluster


coils of wireGauge
calledhas
thethe
bobbin. One coil
features:-
-
> Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation > With Conventional Instrument Cluster > Page 3090


ThisHgauge
-
13,000 ohms 200 ohms 13,000 ohms
-
Diagnostic Bars
200 ohms
When the
Diagnostic topontwo
bars thisand bottom
gauge two bars
coolant gauge,
temperature a short
sender circuit
is lower thanmay
thebe
o
Fail Safe Cooling
(124C)
Allthe
Once eight
is met:-
(166C)
Allthe
is met:-
is mounted
sender:-
-
> Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation > Page 3091

REMOVAL
INSTALLATION
> Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications
Thermostat: Specifications
Thermostat Opening Temperature
Starts to Open ...................................................................................................................................................................

> Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 3095
Thermostat: Description and Operation
cylinder
When block is cold, the water thermostat is in the closed position and the engine coolant flow is restricted to
the coolant
- intake manifold
- cylinder head
- Heater core
Theengine
As the water thermostat opens allowing
coolant temperature a portion of the coolant to pass into the radiator.
increases:-
-
Simultaneously, the bypass passage internal to the intake manifold, cylinder head and cylinder block is closed
Thermostat: Testing and Inspection
When investigating a concern of overheating or an insufficient heater/defroster performance, perform the followi
1. Check and service any leaks in the following components:

- pressure relief cap
- heater water hose
- radiator and degas system hoses
- water hose connection
- head gasket
- water pump housing gasket
2. Check the cold engine coolant level in the degas bottle.

a. If the level is below the cold fill level, fill to the cold fill level with a 50/50 mixture of Ford Premium Cooling
(green), Ford Extended Life Engine Coolant F6AZ-19544-AA (orange), or equivalent.
b. If the engine coolant drops below the cold fill level, add coolant to bring level back to the cold fill level. Repea
the air is purged from the engine cooling system.
When this procedure has been completed feel the heater inlet and outlet hoses and the underside of the upper r
Thermostat: Service and Repair

REMOVAL
CAUTION:
Do not mix Standard (green) Coolant with Extended Life Coolant (orange). If this contamination occurs the servi
1. Partially drain the engine cooling system so that the engine coolant level is below the water thermostat.
2. Disconnect the upper radiator hose from the water hose connection.
3. Remove the two water outlet connection retaining bolts.4. Remove the water hose connection gasket and water the
replace if necessary.
INSTALLATION
20-30 Nm (15-22 ft. lbs.).
1. Install the water thermostat, water hose connection gasket and water hose connection as shown.2. Install and altern
Coolant F6AZ-19544-AA (orange) or equivalent.
5. Start the engine and check all hoses and connections for leaks. Allow the engine to warm up so that the water therm
bottle as required to maintain minimum cold fill level.
> Engine, Cooling and Exhaust > Cooling System > Water Pump > Drive Pulley, Water Pump > Component Information > Specifications
Drive Pulley: Specifications

Water Pump Pulley Bolt ...................................................................................................................................................
> Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest for Catalyst Shield: >
System - Buzzing/Rattling Noise
Catalyst Shield: Customer InterestExhaust System - Buzzing/Rattling Noise
Article No.98-20-10
10/12/98
^
EXHAUST SYSTEM - LOOSE CATALYST ORMUFFLER HEAT SHIELDS
^
NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS
FORD:1993 FESTIVA1993-94 TEMPO1993-97 PROBE, THUNDERBIRD1993-99 CROWN VICTORIA, ESCORT,
LINCOLN-MERCURY:1993-94 CAPRI, TOPAZ1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABL
LIGHT TRUCK:1993-96 BRONCO1993-97 F SUPER DUTY, F-35O1993-99 AEROSTAR, ECONOLINE, EXPLOR

This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehic
ACTIONInstall worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for det
SERVICE PROCEDURE
1.
Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Wor
NOTE
UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BE

ISSUEA "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the
> 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 3112

2.
Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for t
3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as re
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").

FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2")

W705949-S300 Worm clamp (3/4" To 4")
SUPERSEDES: 98-6-4
WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper W
> 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 3113

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

> Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cata
Exhaust System - Buzzing/Rattling Noise
Catalyst Shield: All Technical Service BulletinsExhaust System - Buzzing/Rattling Noise
Article No.98-20-10
10/12/98
^
^

SERVICE PROCEDURE
1.
NOTE

> 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 3119

2.


W705949-S300 Worm clamp (3/4" To 4")
SUPERSEDES: 98-6-4
> 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 3120


DEALER CODING
CONDITION
BASIC PART NO. CODE
5E258 33
OASIS CODES: 403000, 702000, 702100, 702200, 703000

> Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications
Exhaust Manifold: Specifications
Exhaust Manifold to Cylinder Head Nut: 18-22 Nm (14-16 Ft. Lbs.)Exhaust Manifold-to-Catalytic Converter Nuts:
> Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 3124
Exhaust Manifold: Testing and Inspection

CLEANING
Remove all gasket or foreign material from all inlet and outlet sealing surfaces of the exhaust manifolds.
INSPECTION
Inspect the cylinder head joining flanges of the exhaust manifolds for evidence of exhaust gas leaks.
Inspect the exhaust manifolds for cracks, damaged gasket surfaces or other damage that would make them unfit for f
> Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal
Exhaust Manifold: Service and RepairRemoval
1. Disconnect battery ground cable. 2. Remove air cleaner outlet tube. 3. Drain cooling system and remove the fan m
10. Disconnect heater water hose.11. Remove nut retaining ground strap to RH cylinder head.12. Remove heater blow
NOTE:
Two through-bolts are required for LH front engine support insulator and one through-bolt is required for RH fro
18. Remove EGR valve to exhaust manifold tube nut from RH exhaust manifold.
19. Disconnect three way catalytic converter (TWC) from RH and LH exhaust manifolds.20. Lower exhaust and secu
21. For LH exhaust manifold, remove front engine support insulator from cylinder block and remove eight nuts retain
> Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal > Page 3127

25. For RH exhaust manifold, remove eight nuts retaining exhaust manifold to cylinder head and retaining studs and r
exhaust manifold gasket.
Exhaust Manifold: Service and RepairInstallation

37-45 Nm (28-33 ft. lbs.).1. If exhaust manifolds are being replaced, transfer heated oxygen sensors and tighten to A
45-65 Nm (34-48 ft. lbs.).transfer EGR valve tube to manifold connector and tighten to
18-222. Clean mating surfaces of exhaust manifolds and cylinder heads.3. Position exhaust manifold gasket and RH
Nm (14-16 ft. lbs.).
4. Position two exhaust manifold gaskets and LH exhaust manifold to cylinder head and studs and install eight retain
18-22 Nm (14- 16 ft. lbs.). Refer to illustration following Step 3.
35-45 Nm (26-33 ft. lbs.).5. Position and connect EGR valve to exhaust manifold tube to exhaust manifold. Tighten
20-30 Nm (15-22 ft. lbs.).6. Install LH front engine support insulator on cylinder block and tighten bolts to
20-30 Nm (15-22 ft. lbs.).7. Lower engine onto front engine support insulator and remove jack.8. Install front engine
NOTE:
27-41 Nm (20-30 ft. lbs.).9. Remove wire and position three way catalytic converter. Install four nuts and tighten to
NOTE: Make sure exhaust system clears No.3 crossmember. Adjust as necessary.
20-30 Nm (15-22 ft. lbs.).
20-30 Nm (15-22 ft. lbs.).
10. Install oil bypass filter.11. Lower vehicle.12. Connect fuel charging wiring to both heated oxygen sensors.13. Inst

22. Evacuate and recharge air conditioning system.23. Install fan blade and fan shroud. Fill and bleed cooling system.
> Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications
Exhaust Pipe: Specifications

Exhaust Outlet Pipe Frame Bracket Bolts ........................................................................................................................
> Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Exhaust Hanger Insulators
Exhaust Pipe/Muffler Hanger: Service and RepairExhaust Hanger Insulators

Dual Exhaust System - 4.6 L (2V) Engine (Part 1 Of 2)
> Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Exhaust Hanger Insulators > Page 3137


Single Exhaust System - 4.6 L (2V) Engine (Part 1 Of 2)

REMOVAL
1. Raise vehicle on hoist.2. Support exhaust system with a suitable jack stand.3. Remove exhaust hanger insulators fr
INSTALLATION
Exhaust Pipe/Muffler Hanger: Service and RepairExhaust Outlet Pipe Frame Bracket



REMOVAL
1. Raise vehicle on hoist.2. Support exhaust system with a suitable jack stand.3. Remove exhaust hanger insulators fr
INSTALLATION
17-23 Nm (13-16 ft. lbs.).1. Follow removal procedure in reverse order.2. Tighten exhaust outlet pipe frame bracket
> Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 98-20-10 > Oct > 9
Noise
Heat Shield: Customer InterestExhaust System - Buzzing/Rattling Noise
Article No.98-20-10
10/12/98
^
^

SERVICE PROCEDURE
1.
NOTE

> 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 3152

2.


W705949-S300 Worm clamp (3/4" To 4")
SUPERSEDES: 98-6-4
> 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 3153


DEALER CODING
CONDITION
BASIC PART NO. CODE
5E258 33
OASIS CODES: 403000, 702000, 702100, 702200, 703000

> Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 98-20
Buzzing/Rattling Noise
Heat Shield: All Technical Service BulletinsExhaust System - Buzzing/Rattling Noise
Article No.98-20-10
10/12/98
^
^

SERVICE PROCEDURE
1.
NOTE

> 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 3159

2.


W705949-S300 Worm clamp (3/4" To 4")
SUPERSEDES: 98-6-4
> 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 3160


DEALER CODING
CONDITION
BASIC PART NO. CODE
5E258 33
OASIS CODES: 403000, 702000, 702100, 702200, 703000

> Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Page 3161
Heat Shield: Description and Operation

Exhaust shields, consisting of formed metal sheets, attach to the exhaust system or the catalytic converter connec
replacing
Exhaust missing
shields orsubject
are not damaged shields.other than:-
to service
- removal of debris that may collect in the shield area.
If an exhaust shield is damaged or shows evidence of deterioration, it should be replaced rather than serviced.
Converter shields are serviceable by replacing the shield using clamps or bolts. If an exhaust shield is damaged o
Heat Shield: Testing and Inspection

Inspect the exhaust shields for cracks, broken welds, corrosion and damage. Replace the exhaust shield if damaged.
Heat Shield: Service and Repair




NOTE:
- The catalyst welded shields are to be replaced with clamp-on service shields.
-
Removal and Installation procedures involve removing the shield attachments and shield. Installation is the re
> Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications
Muffler: Specifications
Muffler Clamp Nuts .........................................................................................................................................................

> Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Muffler
Muffler: Service and RepairMuffler
WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH
NOTE:
The production muffler and tailpipe assembly is one piece. The service muffler and tail pipe is a two-piece assembly. T
REMOVAL
1. Raise the vehicle on a hoist that permits the rear axle assembly to lower to the full extent of its travel.2. Remove th
NOTE: It may be necessary to heat the inlet pipe-to-muffler joint to ease removal.
INSTALLATION
1. Slide a new muffler clamp over the outlet end of the exhaust inlet pipe.2. Position the muffler on the exhaust inlet
muffler.
3. Position the muffler and install the exhaust hanger insulators. Replace any exhaust hanger insulator showing signs
NOTE:
For ease of assembly, lubricate exhaust hanger insulators with Silicone Lubricant D7AZ-19553-AA or equivalen
> Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Muffler > Page 3172




4. Position the tailpipe and install the exhaust hanger insulators.
NOTE:
For ease of assembly, lubricate the exhaust hanger insulators with Silicone Lubricant D7AZ-19553-AA or equiva
34-46 Nm (26-33 ft. lbs.). 5. Install muffler-to-tailpipe flange gasket, nuts and bolts. Tighten nuts to 6. Align the exh
NOTE:
34-46 Nm (26-33 ft. lbs.)If alignment specifications cannot be obtained, the RH and LH exhaust manifold attach
40-55 Nm (30-40 ft. lbs.).7. Position and alternately tighten the muffler clamp nuts to Make sure the tab and slot are
8. Check the system for leaks and lower the vehicle.

Muffler: Service and RepairMuffler Inlet Pipe

REMOVAL
1. Raise vehicle. 2. Disconnect the heated oxygen sensor electrical connectors.3. Remove the muffler clamps at the m
remove the exhaust outlet pipe frame bracket retaining bolts.
6. When the exhaust inlet pipe is lowered sufficiently, separate the exhaust inlet pipe from the muffler and discard ex
INSTALLATION
1. Remove all exhaust converter outlet gasket material from the outlet flanges on the three way catalytic converters a
without binding.
3. Slide new muffler clamps over the outlet ends of the exhaust inlet pipe.4. Insert the exhaust inlet pipe into the muf
muffler alignment slot.
5. Install new exhaust converter outlet gasket and position the exhaust inlet pipe to the three way catalytic converter.
not tighten the bolts.
6. Install the exhaust outlet pipe frame bracket retaining bolts if removed.




7. Align the system to specification. Refer to applicable illustration.8. With the system held to alignment specificatio
-
40-55Nm (30-40 ft. lbs.). Make sure that the exhaust inlet pipe tab is fully engaged into the muffler alignmen
- 17-23 Nm (13- 16 ft. lbs.),
34-46 Nm (26-33 ft. lbs.).Tighten the exhaust outlet pipe frame bracket bolts to if required. Tighten the exha
- 34-46 Nm (26-33 ft. lbs.).Alternately tighten the RH and LH exhaust manifold nuts to
NOTE:
Alternate tightening of joint fasteners is required to provide uniform clamping in order to prevent joint distortion,
9. Remove alignment restraints and support wire.
10. Connect heated oxygen sensor electrical connectors.11. Check the exhaust system for leaks and proper alignment.
> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information >
Controls - General PCM Programming Procedures
TSB 04-24-14
12/13/04

SERVICE PROCEDURE
> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component

NOTE
1.
NOTE
a.
a.
NOTE

7.
11.
14.
Disclaimer
Controls - General PCM Programming Procedures > Page 3190
Article No.99-4-3
03/08/99

SUPERSEDES: 98-26-3
OASIS CODES: 203000, 206000, 290000, 690000, 698298
3192

3193

Engine View
Instructions

- System Diagrams
- Grounds Diagrams


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:



-

(NGS)
Page 3208

(DTCs).
-The Clears
occur when Trouble
a PCM reset Codes
is performed:
- Clears the DTCs.
- Sets DTC P1000.
NOTE: (NGS)


Page 3209
(PCM)
> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Integrated Control Relay Module > Component Infor
Relay Center (C110)

> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component In

Engine View
> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System)

Relay Center (C110)
> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locatio

Engine View
> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component

Relay Center (C110)
> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagra
Instructions

- System Diagrams
- Grounds Diagrams


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:

(PCM)
> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Integrated Control Relay Module > Component Inform
Relay Center (C110)

> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component In

Engine View
> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) >

Relay Center (C110)
> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations

> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Pag

PURPOSE
- (ICM) (PCM)
OPERATION
-
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information
Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms
Article No.98-23-10
11/23/98
SERVICE TIP

> 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 for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page
3255

voltage at idle.
NOTE
Symptoms
^ Lack of Power
^ Buck/Jerk
OBDII DTCs
OBDI DTCs
NOTE:
3256

1.
NOTE
NOTE
2.
3.
4.
NOTE
BAROTO
DUE ISINCREASINGLY
VEHICLE IS AT HIGH
REQUIREMENTS,
THROTTLE OPENINGS.
IT IS POSSIBLE
THEREFORE,
FOR SOME
A VV
Article No.98-23-10
11/23/98
SERVICE TIP

Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability
Symptoms > Page 3262

voltage at idle.
NOTE
Symptoms
^ Lack of Power
^ Buck/Jerk
OBDII DTCs
OBDI DTCs
NOTE:

1.
NOTE
NOTE
2.
3.
4.
NOTE
BAROTO
DUE ISINCREASINGLY
VEHICLE IS AT HIGH
REQUIREMENTS,
THROTTLE OPENINGS.
IT IS POSSIBLE
THEREFORE,
FOR SOME
A VV
3264

3265

Engine View
3266

3267

- (PCM)
3268

CAUTION:
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Informatio



REMOVAL
CMP
INSTALLATION
sensor.
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Compute
Specifications

ECT Sensor ..........................................................................................................................................................................

Engine View
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch
(For Computer) > Component Information > Specifications > Page 3279

Engine View
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch
(For Computer) > Component Information > Specifications > Page 3280

Engine View

ECT
NOTE:
ECT
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Informat


Engine View
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor >

CKP
REMOVAL
CKP
INSTALLATION
position sensor.
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Informati

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Informati

REMOVAL
INSTALLATION
System/Testing and Inspection
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Infor

Engine View

IAT
(PCM)

NOTE: IAT
90 degrees
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Techn
Engine Controls - Driveability Diagnosis
Article No.01-9-7
05/14/01
Information
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component


^ GND - Ground
^ HC - Hydrocarbons




^
^
^







^
NOTE

^
^

^
^


(P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152).


NOTE

4.
5.
2.


NOTE
2.
3.

1.
2.
3.
a.
b.
c.
4.

HO2S to Converter ..............................................................................................................................................................
H02S Location
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagra
Instructions

- System Diagrams
- Grounds Diagrams


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:

-
TheAheated
low voltage
the oxygen lean
thecondition.

Description
Tool Number
- 303-476 (T94P-9472-A)

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Compo

Page 3337

Engine View
Page 3338
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information




TP
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range (TR) Sensor <--> [Tra
T] > Component Information > Locations
Transmission View

T] > Component Information > Locations > Page 3349

7 - 10 Nm (62 - 88 inch lbs.).
19 - 26 Nm (14 - 19 ft. lbs.)
REMOVAL
INSTALLATION
(TR)
7 - 10 Nm (62-88 inch lbs.)
19 - 26 Nm (14 - 19 ft. lbs.)
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information >
Transmission View

Instructions

- System Diagrams
- Grounds Diagrams
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
(VSS) (PCM)
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component I

3370

Engine View
3371
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information >
Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms
Article No.98-23-10
11/23/98
SERVICE TIP

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
3381

voltage at idle.
NOTE
Symptoms
^ Lack of Power
^ Buck/Jerk
OBDII DTCs
OBDI DTCs
NOTE:
3382

1.
NOTE
NOTE
2.
3.
4.
NOTE
BAROTO
DUE ISINCREASINGLY
VEHICLE IS AT HIGH
REQUIREMENTS,
THROTTLE OPENINGS.
IT IS POSSIBLE
THEREFORE,
FOR SOME
A VV
Article No.98-23-10
11/23/98
SERVICE TIP


voltage at idle.
NOTE
Symptoms
^ Lack of Power
^ Buck/Jerk
OBDII DTCs
OBDI DTCs
NOTE:

1.
NOTE
NOTE
2.
3.
4.
NOTE
BAROTO
DUE ISINCREASINGLY
VEHICLE IS AT HIGH
REQUIREMENTS,
THROTTLE OPENINGS.
IT IS POSSIBLE
THEREFORE,
FOR SOME
A VV
3390

3391

Engine View
3392

3393

- (PCM)
3394

CAUTION:
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Informatio

WARNING:
-
-
-M2C153-G.
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Informat
Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement

99B03
Dealer Letter
Administrative
^ Refund Codes
Labor Allowances
Attachment II^
TechnicalIII^

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Page 3406

Page 3407

PROMPTLY CORRECT

Page 3408

LABOR ALLOWANCES
PARTS REQUIREMENTS
CLAIMS PREPARATION

SERVICE PROCEDURE
1. Open trunk.
Page 3409


Page 3410

5.

Page 3411


Page 3412

20. Close trunk.

Page 3413

Page 3414

Page 3415

All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement

99B03
Dealer Letter
Administrative
^ Refund Codes
Labor Allowances
Attachment II^
TechnicalIII^



PROMPTLY CORRECT


LABOR ALLOWANCES
PARTS REQUIREMENTS
CLAIMS PREPARATION

SERVICE PROCEDURE
1. Open trunk.



5.




20. Close trunk.




Page 3431
Information and Instructions

- System Diagrams
- Grounds Diagrams


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
(IFS)
REMOVAL
IFS
INSTALLATION
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information




TP
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specificatio



REMOVAL
CMP
INSTALLATION
sensor.
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specificati


Engine View
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component

CKP
REMOVAL
CKP
INSTALLATION
position sensor.
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Info
> Locks - Lock Service Packages Available
Article No.99-24-2
11/29/99

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder >


NOTE

^
^
NOTE

NOTE

NOTE
NOTE

Cylinder Inoperative

NOTE:
REMOVAL
drill.
INSTALLATION
Cylinder Inoperative > Page 3476
REMOVAL
INSTALLATION
> Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications

> Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 3482

> Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 3483

REMOVAL
INSTALLATION
7.75 Nm (68 lb in)
> Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications

Hot Idle ................................................................................................................................................................................
> Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 3487

> Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation

-
> Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation > Page 3492

> Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation > Page 3493
REMOVAL
INSTALLATION
> Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions
NOTE
> Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3498
Fuel Pressure Gauge
Special Tool(s)
> Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications
Firing Order 1-3-7-2-6-5-4-8
Coil On Plug
> Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations
> Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap
Spark Plug Gap .................................................................................................................................................................. 1

> Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 3510
Spark Plug Gap .................................................................................................................................................................. 1

> Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3511

Spark Plug Type ...................................................................................................................................................................




REMOVAL
INSTALLATION
> Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications
> Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Compression Test

TEST RESULTS
> Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Compression Test > Page 3521
Example Readings
> Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications

> Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sens
Lean Driveability Symptoms
Article No.98-23-10
11/23/98
SERVICE TIP

> 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 3534

voltage at idle.
NOTE
Symptoms
^ Lack of Power
^ Buck/Jerk
OBDII DTCs
OBDI DTCs
NOTE:
> Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air

1.
NOTE
NOTE
2.
3.
4.
NOTE
> Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flo
98 > Engine - Lean Driveability Symptoms
Article No.98-23-10
11/23/98
SERVICE TIP

> 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 3541

voltage at idle.
NOTE
Symptoms
^ Lack of Power
^ Buck/Jerk
OBDII DTCs
OBDI DTCs
NOTE:
> Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service

1.
NOTE
NOTE
2.
3.
4.
NOTE
> Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3543


Engine View


- (PCM)

CAUTION:
> Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations

Engine View
> Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3551

IAT
(PCM)
> Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3552

NOTE: IAT
90 degrees
> Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications

> Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3556


REMOVAL
CMP
INSTALLATION
sensor.
> Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications

ECT Sensor ..........................................................................................................................................................................
> Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3562

Engine View

Engine View

Engine View

ECT
NOTE:
ECT
> Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications

> Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3570

Engine View

CKP
REMOVAL
CKP
INSTALLATION
position sensor.
> Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations
Data Link Connector: Locations

The Data Link Connector is located behind the LH side of the instrument panel.
> Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions
Data Link Connector: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page
3579

3580

System Diagrams
3581

Grounds Diagrams
3582

ELECTRICAL SYMBOLS
Electrical Symbols
3583

Electrical Symbols
VACUUM SYMBOLS
3584

Vacuum Symbols

BK
BL
BR
3585

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3586
Data Link Connector

> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programm
TSB 04-24-14
12/13/04

SERVICE PROCEDURE
> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General
PCM Programming Procedures > Page 3591

NOTE
1.
NOTE
a.
a.
NOTE

7.
11.
14.
Disclaimer
> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programm
Article No.99-4-3
03/08/99

SUPERSEDES: 98-26-3
OASIS CODES: 203000, 206000, 290000, 690000, 698298
> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3595

> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3596

Engine View
> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page
3599

3600

System Diagrams
3601

Grounds Diagrams
3602

ELECTRICAL SYMBOLS
Electrical Symbols
3603

Electrical Symbols
VACUUM SYMBOLS
3604

Vacuum Symbols

BK
BL
BR
3605

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3606

3607

> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 3608

-
> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures

(NGS)
> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3611

(DTCs).
-The Clears
occur when Trouble
a PCM reset Codes
is performed:
- Clears the DTCs.
- Sets DTC P1000.
NOTE: (NGS)


> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3612
(PCM)
> Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations

> Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3616

REMOVAL
INSTALLATION
> Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Specifications
Idle Speed/Throttle Actuator - Electronic: Specifications

Idle Air Control Valve to Intake Manifold Bolts .................................................................................................................
(*) Tighten to 8-10 Nm (71-88 lb in), then rotate bolts 85-95 degrees.
> Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Specifications > Page 3620
Idle Speed/Throttle Actuator - Electronic: Service Precautions

CAUTION:
Do not use Carburetor Tune-Up Cleaner D9AZ-19579-BA meeting Ford specification ESR-M14P9-A or any other typ
IACThe Idle Air Control valve ( valve) cannot be cleaned. It must be replaced.
> Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Specifications > Page 3621
Idle Speed/Throttle Actuator - Electronic: Description and Operation
IAC
(PCM)The Idle Air Control valve ( valve) controls engine idle speed. The idle air control valve is mounted on the intak
> Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information an
Multiplex Communication Network: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information an
Multiplex Communication Network: Electrical Diagrams
Multiplex Communication Network (Part 1 Of 2)


Multiplex Communication Network (Part 2 Of 2)
> Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Flow of Di
Multiplex Communication Network: Flow of Diagnosis
Multiplex Communication Network
The multiplex communication network provides:

-
- (DLC)
a common link for communication to an off-board tester through the Data Link Connector located under the inst
The micro-processor based subsystems included on this network are:

- powertrain control
- climate control
- anti-lock brakes
- anti-theft system
(NGV)A fifth subsystem, the Natural Gas Vehicle Module:

- is used only on Crown Victoria Natural Gas Vehicles (NGV).
- utilizes a stand-alone processor to control the fuel indication system (fuel indication is not supported by the multi
- (PCM)uses the multiplex communication network to communicate with the Powertrain Control Module .
(DLC)The multiplex communication bus between these subsystems and the Data Link Connector consist of:
- the ability for module-to-module communication by sharing required inputs and outputs instead of each compone
Circuit 914twisted
an unshielded (T/O) bus(+).
pair of wires:-
- Circuit 915 (PK/LB) bus(-).
Fault Tolerance
Theone circuit is
multiplex severed.
communication network will remain operational in the event:-
- one circuit is shorted to ground.
- one circuit is shorted to battery positive voltage (B+).
- a termination resistor is lost within a module.
> Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and
Inspection > Flow of Diagnosis > Page 3637

- one or more modules tail internally.
(DTC)Any of these conditions will be detected and reported to the off-board tester during diagnostics in the form
Purpose The information is designed to diagnose multiplex communication network concerns.
affect
These normalmay:-
concerns functional operations of the vehicle.
- be directly related to customer concerns.
- be undetectable except during diagnostics.
To properly diagnose a network concern, follow the diagnostic procedure in the order presented.
Module Identification Modules included on this multiplex communication network include:
located incontrol
Powertrain the engine compartment
module - on the passenger side of the dash panel.
- (PCM)a failure of the communication network to the Powertrain Control Module may result in a no start
- if communication to the powertrain control module fails during diagnosis, refer to Inspection and Verifica
located in
Electronic the centerTemperature
Automatic of the instrument panel.(EATC) Module -
Control
- (PCM)loss of communication to Powertrain Control Module may result in degraded automatic temperatu
-
if communication to the electronic automatic temperature control module is lost, refer to Electronic Clima
natural
Natural GasgasVehicle
vehicles(NGV)
only. Module -
- located in front of the A/C condenser core behind the radiator grille.
- (NGV)
if communication to the Natural Gas Vehicle Module fails, refer to Instrument cluster - Natural Gas Vehi
located in
Anti-Lock the lower
Brake LH Module
Control side of the
- engine compartment.
- a failed anti-lock brake module may cause a no communication condition on the diagnostic communicatio
- if communication to the anti-lock brake module fails, refer to Anti-Lock Brake System for No Communic
enables
Passive and disables
Anti-Theft vehicle
System from (PATS)
Control starting. Module -
- located under left hand side of instrument cluster.
-
if communication to the PATS module is lost, refer to Anti-Theft and Alarm Systems. See: Accessories an
Inspection and Verification
1. Verify the customer's original concern.2. Visually inspect for obvious signs of electrical damage:

Fuses -
Electrical
- Wiring harness
- Loose or corroded connections
- Anti-lock brake control module (optional)
- (DDM)Driver Door Module (optional)
- (EATC)Electronic Automatic Temperature Control module (optional)
- (ECS)Electronic Crash Sensor module
- (LCM)Lighting Control Module
- (NGVM)Natural Gas Vehicle Module (optional)
- (PATS)Passive Anti-Theft System module
(NGS) (DLC)3. If the concern remains after the inspection, connect New Generation STAR Tester to the Data Link

Check that
instrument theand
panel program
select card is properly
the vehicle to beinstalled.
tested from NGS Tester menu. If NGS Tester does not communicate
- Check the connections to the vehicle.
- Check the ignition switch position.
If NGS Tester still does not communicate with the vehicle, go to Pinpoint Test M. See: Pinpoint Tests/M: No
Diagnostic Communication Network
The diagnostic communication network:

- consists of a single wire, Circuit 70 (LB/W).
- (DLC)
provides a common link for communication to an off-board tester through the Data Link Connector located unde
- does not allow module-to-module communications.

- supplemental air bag system
- keyless entry
- power locks and windows
- interior lighting control
- warning indicator control
Fault Tolerance
The
- Circuit
diagnostic
70 (LB/W)
communication
shorted tonetwork
ground.
battery will fail ifvoltage
positive any of(B+).
the following occur:-
- the module loses power or ground supply.
- a module failure shorts the communication network internally.
Purpose
Theaffect normal isfunctional
information designed operations
to diagnoseofany
thediagnostic
vehicle. communication network concerns. These concerns may:-

Module Identification Modules included on this diagnostic communication network include:
located behind
Electronic the instrument
Crash Sensor - panel to the right of the steering column.
- a failed ECS may cause a no communication condition on the diagnostic communication network.
-
if communication to the electronic crash sensor fails, refer to Safety Belts for No Communication testing.
located
Driver Doorbehind driver
Module - front door trim panel.
- if communication to the driver door module fails, refer to Windows and Glass for No Communication test
locatedControl
Lighting behind Module
the instrument
- panel to the right of the steering column.
- if communication to the lighting control module fails, refer to Lighting and Horns for No Communication
Multiplex Communication Network: Initial Inspection and Diagnostic Overview
Multiplex Communication Network
The multiplex communication network provides:

-
- (DLC)
a common link for communication to an off-board tester through the Data Link Connector located under the inst

- powertrain control
- climate control
- anti-lock brakes
- anti-theft system
(NGV)A fifth subsystem, the Natural Gas Vehicle Module:

- is used only on Crown Victoria Natural Gas Vehicles (NGV).
- utilizes a stand-alone processor to control the fuel indication system (fuel indication is not supported by the multi
- (PCM)uses the multiplex communication network to communicate with the Powertrain Control Module .
(DLC)The multiplex communication bus between these subsystems and the Data Link Connector consist of:
- the ability for module-to-module communication by sharing required inputs and outputs instead of each compone
Circuit 914twisted
an unshielded (T/O) bus(+).
pair of wires:-
- Circuit 915 (PK/LB) bus(-).
Fault Tolerance
Theone circuit is
multiplex severed.
communication network will remain operational in the event:-
- one circuit is shorted to ground.
- one circuit is shorted to battery positive voltage (B+).
- a termination resistor is lost within a module.

- one or more modules tail internally.
(DTC)Any of these conditions will be detected and reported to the off-board tester during diagnostics in the form
Purpose The information is designed to diagnose multiplex communication network concerns.
affect
These normalmay:-
concerns functional operations of the vehicle.
Module Identification Modules included on this multiplex communication network include:
located incontrol
Powertrain the engine compartment
module - on the passenger side of the dash panel.
- (PCM)a failure of the communication network to the Powertrain Control Module may result in a no start
- if communication to the powertrain control module fails during diagnosis, refer to Inspection and Verifica
located in
Electronic the centerTemperature
Automatic of the instrument panel.(EATC) Module -
Control
- (PCM)loss of communication to Powertrain Control Module may result in degraded automatic temperatu
-
if communication to the electronic automatic temperature control module is lost, refer to Electronic Clima
natural
Natural GasgasVehicle
vehicles(NGV)
only. Module -
- located in front of the A/C condenser core behind the radiator grille.
- (NGV)
if communication to the Natural Gas Vehicle Module fails, refer to Instrument cluster - Natural Gas Vehi
located in
Anti-Lock the lower
Brake LH Module
Control side of the
- engine compartment.
- a failed anti-lock brake module may cause a no communication condition on the diagnostic communicatio
- if communication to the anti-lock brake module fails, refer to Anti-Lock Brake System for No Communic
enables
Passive and disables
Anti-Theft vehicle
System from (PATS)
Control starting. Module -
- located under left hand side of instrument cluster.
-
if communication to the PATS module is lost, refer to Anti-Theft and Alarm Systems. See: Accessories an
Inspection and Verification
1. Verify the customer's original concern.2. Visually inspect for obvious signs of electrical damage:

Fuses -
Electrical
- Wiring harness
- Loose or corroded connections
- Anti-lock brake control module (optional)
- (DDM)Driver Door Module (optional)
- (EATC)Electronic Automatic Temperature Control module (optional)
- (ECS)Electronic Crash Sensor module
- (LCM)Lighting Control Module
- (NGVM)Natural Gas Vehicle Module (optional)
- (PATS)Passive Anti-Theft System module
(NGS) (DLC)3. If the concern remains after the inspection, connect New Generation STAR Tester to the Data Link

Check that
instrument theand
panel program
select card is properly
the vehicle to beinstalled.
tested from NGS Tester menu. If NGS Tester does not communicate
- Check the connections to the vehicle.
- Check the ignition switch position.
If NGS Tester still does not communicate with the vehicle, go to Pinpoint Test M. See: Pinpoint Tests/M: No
Diagnostic Communication Network
The diagnostic communication network:

- consists of a single wire, Circuit 70 (LB/W).
- (DLC)
provides a common link for communication to an off-board tester through the Data Link Connector located unde
- does not allow module-to-module communications.

- supplemental air bag system
- keyless entry
- power locks and windows
- interior lighting control
- warning indicator control
Fault Tolerance
The
- Circuit
diagnostic
70 (LB/W)
communication
shorted tonetwork
ground.
battery will fail ifvoltage
positive any of(B+).
the following occur:-
- the module loses power or ground supply.
- a module failure shorts the communication network internally.
Purpose
Theaffect normal isfunctional
information designed operations
to diagnoseofany
thediagnostic
vehicle. communication network concerns. These concerns may:-

Module Identification Modules included on this diagnostic communication network include:
located behind
Electronic the instrument
Crash Sensor - panel to the right of the steering column.
- a failed ECS may cause a no communication condition on the diagnostic communication network.
-
if communication to the electronic crash sensor fails, refer to Safety Belts for No Communication testing.
located
Driver Doorbehind driver
Module - front door trim panel.
- if communication to the driver door module fails, refer to Windows and Glass for No Communication test
locatedControl
Lighting behind Module
the instrument
- panel to the right of the steering column.
- if communication to the lighting control module fails, refer to Lighting and Horns for No Communication
Communication Systems Diagnostics

Before proceeding with network communication system diagnostics:
- review equipment level of vehicle.
- make note of module and systems vehicle is equipped with.
- (NGS)
New Generation STAR Tester will retrieve NO RESPONSE/NOT EQUIPPED for any module the vehicle is not
After the equipment level has been reviewed, proceed with Pinpoint Test A to continue with network communica
Multiplex Communication Network: Pinpoint Tests
Pinpoint Test Notes

CAUTION:
-
Be careful when probing the fuse junction panel, power distribution box or any connectors. Damage will result to
- Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result.
NOTE:
-
If DTCs are recorded and the symptom is not present when performing the pinpoint tests, an intermittent concern
- (NGS)
Use Rotunda 73 Digital Multimeter 105-R0051 and New Generation STAR Tester 418-F048 (007-00500) or equ
The No Communication test must be performed to verify power and ground to the suspect module before performing a
Do not perform any of the pinpoint tests unless you are so instructed. Each pinpoint test assumes that a fault has been d
Do not replace any parts unless the test results indicate they should be replaced.
When more than one DTC is received, always start with the first DTC received.
Follow correct pinpoint test procedures steps in order as listed. Follow each step until a condition is found.
After completing any repairs to the communication system, verify all components are properly reconnected, then clear
A1 - A4

B1 - B4
C1 - C3

D1 - D4
E1 - E2

F1 - F2
G1 - G2
H1 - H2

J1 - J6

K1 - K8
L: No Module/Network Communication - Multiplex

L1 - L2

L3 - L8

L9 - L12

M1 - M5
> Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Page 3654
Multiplex Communication Network: Tools and Equipment
New Generation Star (NGS) Tester .....................................................................................................................................

> Powertrain Management > Computers and Control Systems > Integrated Control Relay Module > Component Information > Diagrams
Relay Center (C110)

> Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations

Engine View
> Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3661

Relay Center (C110)
> Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation
> Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnos
Article No.01-9-7
05/14/01
Information
> Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls -
Driveability Diagnosis > Page 3669


^ GND - Ground
^ HC - Hydrocarbons




^
^
^







^
NOTE

^
^

^
^


(P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152).


NOTE

4.
5.
2.


NOTE
2.
3.

1.
2.
3.
a.
b.
c.
4.
> Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 3684

HO2S to Converter ..............................................................................................................................................................
> Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 3685
H02S Location
> Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3688


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:

> Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3696
-
TheAheated
low voltage
the oxygen lean
thecondition.

Description
Tool Number
- 303-476 (T94P-9472-A)

> Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications

> Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3703

Engine View
> Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3704
> Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Serv
General PCM Programming Procedures
TSB 04-24-14
12/13/04

SERVICE PROCEDURE
> 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 3710

NOTE
1.
NOTE
a.
a.
NOTE

7.
11.
14.
Disclaimer
General PCM Programming Procedures > Page 3712
Article No.99-4-3
03/08/99

SUPERSEDES: 98-26-3
OASIS CODES: 203000, 206000, 290000, 690000, 698298


Engine View
> Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Di

- System Diagrams
- Grounds Diagrams
Diagrams > Diagram Information and Instructions > Page 3718


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Di
Page 3725


> Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Pa

-
> Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Re

(NGS)

(DTCs).
-The Clears
occur when Trouble
a PCM reset Codes
is performed:
- Clears the DTCs.
- Sets DTC P1000.
NOTE: (NGS)


(PCM)
> Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Integrated Control Relay Module > Component Information > Diagr
Relay Center (C110)

> Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > L

Engine View
> Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component

Relay Center (C110)
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Serv
98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms
Article No.98-23-10
11/23/98
SERVICE TIP

> 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 3748

voltage at idle.
NOTE
Symptoms
^ Lack of Power
^ Buck/Jerk
OBDII DTCs
OBDI DTCs
NOTE:
Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3749

1.
NOTE
NOTE
2.
3.
4.
NOTE
Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms
Article No.98-23-10
11/23/98
SERVICE TIP

Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3755

voltage at idle.
NOTE
Symptoms
^ Lack of Power
^ Buck/Jerk
OBDII DTCs
OBDI DTCs
NOTE:
Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3756

1.
NOTE
NOTE
2.
3.
4.
NOTE
Bulletins for Air Flow Meter/Sensor: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
Fuel Filler Neck: All Technical Service BulletinsEmissions - 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 LAMPILLUMIN
FORD:1997-2000 CONTOUR1997-2002 ESCORT1997-2003 CROWN VICTORIA, MUSTANG, TAURUS1998-200
LINCOLN:1997-1998 MARK VIII1997-2002 CONTINENTAL1997-2003 TOWN CAR2000-2003 LS1998-2003 NA
MERCURY:1997-1999 TRACER1997-2000 MYSTIQUE1997-2003 GRAND MARQUIS, SABLE1999-2002 COUG

This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures.
ISSUESome vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (D
ACTIONUse the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in
Definitions of Acronyms
^ CVS Canister Vent Solenoid
^ DTC Diagnostic Trouble Code
^ EVAP Evaporative Emissions System
^ EVMV Electronic Vapor Management Valve
^ FTP Fuel Tank Pressure
Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON >
Page 3762

^ 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
NOTE
MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DUR
OVERVIEW OF TEST PROCEDURES
Page 3763

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

Page 3764

^ 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 Purg
4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100
5.
If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and procee
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 C
2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicatin
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 P
Page 3765

WARNING
DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PO
5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Cani
NOTE
6.
Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thu
7.
For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remot
8.
Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use th
LEAK VERIFICATION (METERED AIR SYSTEM)
1. Position the selector valve located on the Smoke Machine control panel to "METER".
2. SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOC
Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (t
3.
TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the
NOTE
THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITER
Page 3766

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 wil
7. Leak Verification After Repair
a.
If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remo
b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCED
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.
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 i
12.
For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and
Disclaimer
Page 3772

SERVICE PROCEDURE
NOTE
NOTE
Page 3773

NOTE

Page 3774

3.
5.
1.
4.
Page 3775

WARNING
NOTE
6.
7.
8.
2. SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOC
3.
NOTE
Page 3776

6.
a.
11.
12.
Disclaimer


Engine View


- (PCM)

CAUTION:
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specificatio



REMOVAL
CMP
INSTALLATION
sensor.
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component

ECT Sensor ..........................................................................................................................................................................
3791

Engine View
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer
) > Component Information > Specifications > Page 3792

Engine View
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer
) > Component Information > Specifications > Page 3793

Engine View
3794

ECT
NOTE:
3795
ECT
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specificat


Engine View
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component

CKP
REMOVAL
CKP
INSTALLATION
position sensor.
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations

REMOVAL
INSTALLATION
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locati

Engine View

IAT
(PCM)

NOTE: IAT
90 degrees
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bul
Driveability Diagnosis
Article No.01-9-7
05/14/01
Information
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information >
Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3816


^ GND - Ground
^ HC - Hydrocarbons




^
^
^







^
NOTE

^
^

^
^


(P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152).


NOTE

4.
5.
2.


NOTE
2.
3.

1.
2.
3.
a.
b.
c.
4.

HO2S to Converter ..............................................................................................................................................................
H02S Location
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram

- System Diagrams
- Grounds Diagrams


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram
3842

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3843
-
TheAheated
low voltage
the oxygen lean
thecondition.

Description
Tool Number
- 303-476 (T94P-9472-A)

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Informatio


Engine View
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specification




TP
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Digital Transmission Range (TR) Sensor <--> [Transmission Positi
Transmission View


7 - 10 Nm (62 - 88 inch lbs.).
19 - 26 Nm (14 - 19 ft. lbs.)
REMOVAL
INSTALLATION
(TR)
7 - 10 Nm (62-88 inch lbs.)
19 - 26 Nm (14 - 19 ft. lbs.)
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations
Transmission View

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Dia

- System Diagrams
- Grounds Diagrams
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information >


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Pag
(VSS) (PCM)
> Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications

> Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3882



TP
> Powertrain Management > Computers and Control Systems > Digital Transmission Range (TR) Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Loca
Transmission View


7 - 10 Nm (62 - 88 inch lbs.).
19 - 26 Nm (14 - 19 ft. lbs.)
REMOVAL
INSTALLATION
(TR)
7 - 10 Nm (62-88 inch lbs.)
19 - 26 Nm (14 - 19 ft. lbs.)
> Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations
Transmission View

> Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page
3898

3899

System Diagrams
3900

Grounds Diagrams
3901

ELECTRICAL SYMBOLS
Electrical Symbols
3902

Electrical Symbols
VACUUM SYMBOLS
3903

Vacuum Symbols

BK
BL
BR
3904

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3905
(VSS) (PCM)
> Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest for Catalyst Shi
System - Buzzing/Rattling Noise
Catalyst Shield: Customer InterestExhaust System - Buzzing/Rattling Noise
Article No.98-20-10
10/12/98
^
^

SERVICE PROCEDURE
1.
NOTE

> Powertrain Management > Emission Control Systems > 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 3916

2.


W705949-S300 Worm clamp (3/4" To 4")
SUPERSEDES: 98-6-4
> Powertrain Management > Emission Control Systems > 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 3917


DEALER CODING
CONDITION
BASIC PART NO. CODE
5E258 33
OASIS CODES: 403000, 702000, 702100, 702200, 703000

> Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins fo
98 > Exhaust System - Buzzing/Rattling Noise
Article No.98-20-10
10/12/98
^
^

SERVICE PROCEDURE
1.
NOTE

> Powertrain Management > Emission Control Systems > 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 3923

2.


W705949-S300 Worm clamp (3/4" To 4")
SUPERSEDES: 98-6-4
> Powertrain Management > Emission Control Systems > 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 3924


DEALER CODING
CONDITION
BASIC PART NO. CODE
5E258 33
OASIS CODES: 403000, 702000, 702100, 702200, 703000

> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications
Canister Purge Control Valve: Specifications
Evaporative Emission Canister Retaining Nuts ........................................................................................................ 7.6-10

> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 3929
Canister Purge Control Valve: Description and Operation
The evaporative emission canister purge valve:

- is in-line with the evaporative emissions canister.
- controls the flow of fuel vapors out of the evaporative emissions canister.
- closes off vapor flow from the evaporative emissions canister when the engine is not running.
(PCM)
After the engine is started, in response to a signal from the Powertrain Control Module , the evaporative emission canis
> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 3930
Canister Purge Control Valve: Service and Repair
1. Disconnect main emission vacuum control connector from connector port on evaporative emission canister purge
of the dash panel.
7.6-10.4 Nm (68-92 lb in)5. To install, reverse removal procedure. Tighten evaporative emission canister purge valv
system leak check. See: Testing and Inspection/Component Tests/EVAP System Leak Test
6. Perform the Evaporative Emission Running Loss Monitor Repair Verification Drive Cycle. See: Testing and Insp
System Repair Verification
> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Service and Repair
Canister Purge Solenoid: Service and Repair

REMOVAL
1. Remove the evaporative emission canister with bracket assembly.2. Remove canister vent hose.3. Apply upward p
INSTALLATION
1. Follow the removal procedure in reverse order.2. Leak test canister. See: Testing and Inspection/Component Test
> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Description and Operation
Evaporative Check Valve: Description and Operation
The evaporative emission fuel vapor control valve:

- is located in-line between the evaporative emission valve and the evaporative emissions canister.
- closes the flow path from the fuel vapor vent valve to the evaporative emissions canisters during refueling to prev
The evaporative emission fuel vapor control valve is mounted on the fuel tank by an integral bracket.
> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical Service Bulletins >
Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade

> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Technical
Service Bulletins > Recalls for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page 3945





OASIS
You must use OASIS to determine if a vehicle is eligible for this program. Not all CVPI vehicles built in the affected ti
VIN ADDITION OF NON-P71 VEHICLES CURRENTLY IN LAW ENFORCEMENT DUTY
Non-Police Interceptor package Crown Victoria vehicles (P70, P72, P73, P74) currently in law enforcement duty & sub
FINAL ELIGIBILITY CHECK AND REMOVAL OF INELIGIBLE VEHICLES FROM OASIS
In addition to preliminary eligibility verification through OASIS please verify by visual inspection the vehicle is curren
Under 02B02 all CVPI vehicles currently in law enforcement duty can be upgraded at no-charge. Many CVPI vehicles
PLEASE NOTE
If requested by your law enforcement fleet customer correct in-stock vehicles before delivery.
You must contact the Low Volume Coordination Center at 1-800-248-0186 to arrange for parts if you have an involved
An Online Involved Unit Listing will not be available for this program. Not all CVPI vehicles built in the affected time
STATUS OF TECHNICAL SERVICE BULLETIN (TSB) 01-21-14
Optional Upgrade Program 02B02 eliminates the need for TSB 01-21-14. Warranty claims submitted for performing T

OWNER REFUNDS FOR TSB 01-21-14
Ford Motor Company will only refund owner-paid repairs for TSB 01-21-14 made before September 27, 2002 on CVP
Program Code: 02B02
Misc. Expense: REFUND
Misc. Expense: ADMIN
RENTAL CARS

LABOR ALLOWANCES
PARTS ORDERING INFORMATION
LAW ENFORCEMENT VEHICLES:
Beginning October 22, 2002 law enforcement fleets using CVPI vehicles currently in law enforcement duty will be ask
Once on the website the fleet representative will input fleet name contact and vehicle information. The fleet representat
Dealers will then contact the Low Volume Coordination Center and provide the fleets Authorization Number to order p
Fleets who do not register may still order parts through their servicing dealer(s); however priority fulfillment of parts o
Depending upon law enforcement fleet registrations upgrade kits should arrive at your dealership after October 28, 200
OVERVIEW
This procedure provides details for installation of the following:
For all affected vehicles
^ Two (2) rear axle shields
^ One (1) differential cover shield

^ Two (2) fuel tank strap shields
Additional parts required for 1998 through 2003 model year vehicles
^ Two (2) foam pads onto the evaporative emissions canister
^ Replacement of evaporative emissions canister retainer bolts and J-clips (located along the front edge of the can
SERVICE PROCEDURE
1. Raise the vehicle on a hoist.
2. NOTE: Shields are molded with "LH" and "RH" to ease identification.
Install the left and right axle shields being sure to position them so there is clearance between the shield and the s
In some cases, excess weld material on the coil spring seat or stabilizer bar bracket can interfere with clamp insta
3. CAUTION
: Tie straps, which are required for 1998 to 2002 model year vehicles only, have specific heat resistant properties

On 1998 to 2002 model year vehicles, install one (1) tie strap on each shield to secure it to the shock absorber low
4.
On 1992 to 1997 model year vehicles, install the supplied convolute over the ABS circuit wiring leading to each
5. CAUTION: Do not loosen or remove more than three (3) differential cover bolts at any one time or a leak may d
NOTE
: If the axle identification tag (all affected model year vehicles) and/or fluid identification tag (2002 to 2003 mod

Reposition the axle and/or fluid identification tag as necessary. Hand-tighten the bolt(s) at this time. See Figure 5
6.
Remove and discard the three (3) differential cover bolts located at the 4, 6 and 8 o'clock positions. Position the d
17. CAUTION
: The fuel tank strap shields are marked for right and left sides of the vehicle. Be sure to install them in the correc
NOTE:
Spray the area around the fuel tank and strap brackets with silicone lubricant to assist with shield installation.
a) Insert the shield between the fuel tank and the strap from the outside, pushing it in toward the center of the
b) Position the long tab up into the strap bracket.
c) Secure the push-pin retainers into the mating holes in the strap bracket to secure the shield.
d)
Visually check to make sure the shield is correctly positioned. Peel the backing off the adhesive strip and, w
NOTE
^ For 1992 to 1997 model year vehicles, the service procedure is complete. Lower the vehicle.
^ For 1998 to 2003 model year vehicles, continue with this procedure.

8. Remove the two (2) evaporative emissions canister retainer bolts from the front edge along the Z-bracket.
9.
Using a straightedge, draw a line indicating the centerline connecting the (2) two bolt holes. Then, measuring fro
10. CAUTION
: DO NOT drill through the trunk floor when drilling the rivet holes. Place a drill stop or an abundance of tape 12
11.
Remove the one (1) bolt and the two (2) evaporative emissions canister retaining nuts and lower the canister off o
12. Remove and discard the two (2) J-nuts from the evaporative emissions canister flange.

13.
Using Motorcraft Brake Parts Cleaner or equivalent and a clean shop rag, clean the top surface of the canister. Af
14. Reconnect the canister purge valve, then position the evaporative emissions canister and install the two (2) retain
15. CAUTION
: The rivets supplied in the kit provide a high clamp-load and MUST be used. Using rivets other than what is sup
NOTE:
The kit comes with a total of five (5) rivets. Only three (3) are required for this repair. These rivets are very st
Install the three (3) rivets, then tighten the two canister retaining nuts to 6 Nm (53 lb-in).







Attachment I - S1
OASIS
When a customer requests inspection of an Upgrade Kit installation use OASIS to determine eligibility for this inspecti
PLEASE NOTE
Inspect before delivery all upgraded vehicles in stock with build dates on or before October 21, 2002.
^ A part quantity of three (3) [rivets] should be entered on the ACES II claim.
OWNER REFUNDS
Owner refunds are not applicable for this inspection.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this inspection.

Attachment II - S1

LABOR ALLOWANCES FOR 02B02 INSPECTION
Reference the original 02B02 dealer bulletin for first-time Upgrade kit installation labor times and technical instruction
NOTE:
A part quantity of three (3) [rivets] should be entered on the ACES II claim.
ORDER INFORMATION
The DOR/COR for this program is 50287. This number identifies parts ordered for this Customer Satisfaction Program
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
EXCESS STOCK RETURN

Excess stock III
Attachment returned
- S1 for credit must have been purchased from Ford Customer Service Division in accordance with Po
CERTAIN 1998 THROUGH 2003 MODEL YEAR CROWN VICTORIA POLICE INTERCEPTOR (CVPI) VEHICL
KIT INSTALLATION
This procedure involves inspecting the evaporative emissions canister mounting modifications to see if they conform to

Provided here is a check sheet to inspect for proper modification of the evaporative emissions canister mounting. The c
WARNING!
ALL STEPS OF THE ORIGINAL INSTALLATION PROCEDURE MUST BE PERFORMED AS WRITTEN WI
REFER TO THE ATTACHMENT III FOUND ON THE PTS WEBSITE TO VIEW VIDEO CLIPS OF CERTAIN RE
IMPORTANT NOTES
CHECKOFF EACH ITEM AS YOU INSPECT IT, THEN ANSWER WHETHER THE ORIGINAL INSTALLAT
ANY DISCREPANCIES TO THE 02B02 INSTALLATION PROCEDURES MUST BE CORRECTED.
THIS DOCUMENT SHOULD BE SIGNED BY BOTH THE SERVICING TECHNICIAN AND THE SERVICE MA
HAVE A COPY OF THE ORIGINAL 02B02 ATTACHMENT III AVAILABLE FOR REFERENCE DURING THIS
1992 THROUGH 1997 CVPI MODELS ARE NOT INVOLVED IN THIS FOLLOW-UP INSPECTION PROCEDUR
INSPECTION
1. Evaporative Emissions Canister Inspection
WARNING:
DO NOT LEAVE BOLTS AND J-NUTS IN PLACE. THE RIVETS ARE INTENDED TO REPLACE CAN
NOTE:
Field audits have revealed portions of this repair are not being performed properly. Listed here are examples o
^ Bolts and J-nuts still installed - rivets installed (correctly or incorrectly)

^ Bolts and J-nuts still installed - rivets NOT installed
^ Only J-nuts still installed - rivets installed
^ Wrong number of rivets installed
^ Rivets not properly spaced along Z-bracket
^ Rivets installed on wrong Z-bracket flange (securing Z-bracket to floor instead of Z-bracket to evap canister)
If the bolts and/or J-nuts are still installed, they must be removed. If the rivets are installed, they will need to be d

J-nuts. Once they are removed, NEW high clamp-load rivets must be installed as outlined in 02B02 Attachment I
See Figure 1.








Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade

Service Bulletins > All Technical Service Bulletins for Evaporative Emission Control Canister: > 02B02 > Mar > 03 > Campaign - Police Interceptor Optional Upgrade > Page
3978

3979

3980

3981

3982

OASIS
You must use OASIS to determine if a vehicle is eligible for this program. Not all CVPI vehicles built in the affected ti
VIN ADDITION OF NON-P71 VEHICLES CURRENTLY IN LAW ENFORCEMENT DUTY
Non-Police Interceptor package Crown Victoria vehicles (P70, P72, P73, P74) currently in law enforcement duty & sub
FINAL ELIGIBILITY CHECK AND REMOVAL OF INELIGIBLE VEHICLES FROM OASIS
In addition to preliminary eligibility verification through OASIS please verify by visual inspection the vehicle is curren
Under 02B02 all CVPI vehicles currently in law enforcement duty can be upgraded at no-charge. Many CVPI vehicles
PLEASE NOTE
If requested by your law enforcement fleet customer correct in-stock vehicles before delivery.
You must contact the Low Volume Coordination Center at 1-800-248-0186 to arrange for parts if you have an involved
An Online Involved Unit Listing will not be available for this program. Not all CVPI vehicles built in the affected time
STATUS OF TECHNICAL SERVICE BULLETIN (TSB) 01-21-14
Optional Upgrade Program 02B02 eliminates the need for TSB 01-21-14. Warranty claims submitted for performing T
3983

OWNER REFUNDS FOR TSB 01-21-14
Ford Motor Company will only refund owner-paid repairs for TSB 01-21-14 made before September 27, 2002 on CVP
Program Code: 02B02
Misc. Expense: REFUND
Misc. Expense: ADMIN
RENTAL CARS

LABOR ALLOWANCES
PARTS ORDERING INFORMATION
LAW ENFORCEMENT VEHICLES:
Beginning October 22, 2002 law enforcement fleets using CVPI vehicles currently in law enforcement duty will be ask
Once on the website the fleet representative will input fleet name contact and vehicle information. The fleet representat
Dealers will then contact the Low Volume Coordination Center and provide the fleets Authorization Number to order p
Fleets who do not register may still order parts through their servicing dealer(s); however priority fulfillment of parts o
Depending upon law enforcement fleet registrations upgrade kits should arrive at your dealership after October 28, 200
OVERVIEW
This procedure provides details for installation of the following:
For all affected vehicles
^ Two (2) rear axle shields
^ One (1) differential cover shield
3984

^ Two (2) fuel tank strap shields
Additional parts required for 1998 through 2003 model year vehicles
^ Two (2) foam pads onto the evaporative emissions canister
^ Replacement of evaporative emissions canister retainer bolts and J-clips (located along the front edge of the can
SERVICE PROCEDURE
1. Raise the vehicle on a hoist.
2. NOTE: Shields are molded with "LH" and "RH" to ease identification.
Install the left and right axle shields being sure to position them so there is clearance between the shield and the s
In some cases, excess weld material on the coil spring seat or stabilizer bar bracket can interfere with clamp insta
3. CAUTION
: Tie straps, which are required for 1998 to 2002 model year vehicles only, have specific heat resistant properties
3985

On 1998 to 2002 model year vehicles, install one (1) tie strap on each shield to secure it to the shock absorber low
4.
On 1992 to 1997 model year vehicles, install the supplied convolute over the ABS circuit wiring leading to each
5. CAUTION: Do not loosen or remove more than three (3) differential cover bolts at any one time or a leak may d
NOTE
: If the axle identification tag (all affected model year vehicles) and/or fluid identification tag (2002 to 2003 mod
3986

Reposition the axle and/or fluid identification tag as necessary. Hand-tighten the bolt(s) at this time. See Figure 5
6.
Remove and discard the three (3) differential cover bolts located at the 4, 6 and 8 o'clock positions. Position the d
17. CAUTION
: The fuel tank strap shields are marked for right and left sides of the vehicle. Be sure to install them in the correc
NOTE:
Spray the area around the fuel tank and strap brackets with silicone lubricant to assist with shield installation.
a) Insert the shield between the fuel tank and the strap from the outside, pushing it in toward the center of the
b) Position the long tab up into the strap bracket.
c) Secure the push-pin retainers into the mating holes in the strap bracket to secure the shield.
d)
Visually check to make sure the shield is correctly positioned. Peel the backing off the adhesive strip and, w
NOTE
^ For 1992 to 1997 model year vehicles, the service procedure is complete. Lower the vehicle.
^ For 1998 to 2003 model year vehicles, continue with this procedure.
3987

8. Remove the two (2) evaporative emissions canister retainer bolts from the front edge along the Z-bracket.
9.
Using a straightedge, draw a line indicating the centerline connecting the (2) two bolt holes. Then, measuring fro
10. CAUTION
: DO NOT drill through the trunk floor when drilling the rivet holes. Place a drill stop or an abundance of tape 12
11.
Remove the one (1) bolt and the two (2) evaporative emissions canister retaining nuts and lower the canister off o
12. Remove and discard the two (2) J-nuts from the evaporative emissions canister flange.
3988

13.
Using Motorcraft Brake Parts Cleaner or equivalent and a clean shop rag, clean the top surface of the canister. Af
14. Reconnect the canister purge valve, then position the evaporative emissions canister and install the two (2) retain
15. CAUTION
: The rivets supplied in the kit provide a high clamp-load and MUST be used. Using rivets other than what is sup
NOTE:
The kit comes with a total of five (5) rivets. Only three (3) are required for this repair. These rivets are very st
Install the three (3) rivets, then tighten the two canister retaining nuts to 6 Nm (53 lb-in).

3989

3990

3991

3992

3993

3994

Attachment I - S1
OASIS
When a customer requests inspection of an Upgrade Kit installation use OASIS to determine eligibility for this inspecti
PLEASE NOTE
Inspect before delivery all upgraded vehicles in stock with build dates on or before October 21, 2002.
^ A part quantity of three (3) [rivets] should be entered on the ACES II claim.
OWNER REFUNDS
Owner refunds are not applicable for this inspection.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this inspection.

Attachment II - S1
3995

LABOR ALLOWANCES FOR 02B02 INSPECTION
Reference the original 02B02 dealer bulletin for first-time Upgrade kit installation labor times and technical instruction
NOTE:
A part quantity of three (3) [rivets] should be entered on the ACES II claim.
ORDER INFORMATION
The DOR/COR for this program is 50287. This number identifies parts ordered for this Customer Satisfaction Program
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
EXCESS STOCK RETURN

Excess stock III
Attachment returned
- S1 for credit must have been purchased from Ford Customer Service Division in accordance with Po
CERTAIN 1998 THROUGH 2003 MODEL YEAR CROWN VICTORIA POLICE INTERCEPTOR (CVPI) VEHICL
KIT INSTALLATION
This procedure involves inspecting the evaporative emissions canister mounting modifications to see if they conform to
3996

Provided here is a check sheet to inspect for proper modification of the evaporative emissions canister mounting. The c
WARNING!
ALL STEPS OF THE ORIGINAL INSTALLATION PROCEDURE MUST BE PERFORMED AS WRITTEN WI
REFER TO THE ATTACHMENT III FOUND ON THE PTS WEBSITE TO VIEW VIDEO CLIPS OF CERTAIN RE
IMPORTANT NOTES
CHECKOFF EACH ITEM AS YOU INSPECT IT, THEN ANSWER WHETHER THE ORIGINAL INSTALLAT
ANY DISCREPANCIES TO THE 02B02 INSTALLATION PROCEDURES MUST BE CORRECTED.
THIS DOCUMENT SHOULD BE SIGNED BY BOTH THE SERVICING TECHNICIAN AND THE SERVICE MA
HAVE A COPY OF THE ORIGINAL 02B02 ATTACHMENT III AVAILABLE FOR REFERENCE DURING THIS
1992 THROUGH 1997 CVPI MODELS ARE NOT INVOLVED IN THIS FOLLOW-UP INSPECTION PROCEDUR
INSPECTION
1. Evaporative Emissions Canister Inspection
WARNING:
DO NOT LEAVE BOLTS AND J-NUTS IN PLACE. THE RIVETS ARE INTENDED TO REPLACE CAN
NOTE:
Field audits have revealed portions of this repair are not being performed properly. Listed here are examples o
^ Bolts and J-nuts still installed - rivets installed (correctly or incorrectly)

^ Bolts and J-nuts still installed - rivets NOT installed
^ Only J-nuts still installed - rivets installed
^ Wrong number of rivets installed
^ Rivets not properly spaced along Z-bracket
^ Rivets installed on wrong Z-bracket flange (securing Z-bracket to floor instead of Z-bracket to evap canister)
If the bolts and/or J-nuts are still installed, they must be removed. If the rivets are installed, they will need to be d
3997

J-nuts. Once they are removed, NEW high clamp-load rivets must be installed as outlined in 02B02 Attachment I
See Figure 1.
3998

3999

4000

4001

4002

4003

4004

4005

Evaporative Emission Control Canister: Specifications
Evaporative Emission Canister Retaining Nuts ........................................................................................................ 7.6-10

Evaporative Emission Control Canister: Description and Operation
Evaporative emission canister includes the canister vent solenoid.
Fuel vapor emitted through the fuel vapor vent valve is stored in the evaporative emissions canister.
Evaporative Emission Control Canister: Service and Repair
(EVAP canister)
1. Raise vehicle on hoist.2. Remove evaporative emission canister retaining nuts and bolts.3. Partially lower Evapora
vent hose. Disconnect right canister hose from fuel tank vent tube.
7.6-10.4 Nm (68-92 lb in)5. To install, reverse removal procedure. Tighten evaporative emission canister retaining n
check. See: Testing and Inspection/Component Tests/EVAP System Leak Test
6. Perform the Evaporative Emission Running Loss Monitor Repair Verification Drive Cycle. See: Testing and Insp
> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Description and Operation
Evaporative Emissions Hose: Description and Operation

The fuel tank vent tube:
-
transmits stored fuel vapor from the evaporative emissions canister and evaporative emission and brake tube thro
- transmits vent/purge vapor to the evaporative emission vent/purge port.
> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Description and Operation > Page 4012
Evaporative Emissions Hose: Service and Repair
1. Disconnect fuel tank vent tube from evaporative emission and brake tube at RH side of frame.2. Disconnect ignitio
> 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 vapor hose at evaporative emission canister purge valve.2. Remove vapor hose at fuel and vapor return tu
INSTALLATION
1. Follow the removal procedure in reverse order.2. Leak test system. See: Testing and Inspection/Component Tests
Repair Verification
> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Description and Operat
Liquid Vapor Separator: Description and Operation
The fuel vapor vent valve operates as follows:

-
Fuel vapor in the fuel tank is vented to the evaporative emissions canister through the fuel vapor vent valve and t
- The fuel vapor vent valve is mounted in a rubber grommet at a central location in the upper surface of the fuel tan
-
A vapor space between the fuel level and the fuel tank upper surface is combined with an orifice and float shut-of
> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Description and Operat
Liquid Vapor Separator: Service and Repair

REMOVAL
1. Perform fuel pressure release procedure.2. Remove fuel tank.3. Remove evaporative emission valve from top of fu
INSTALLATION
1. Follow removal procedure in reverse order using clean engine oil for ease of installation.
> Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications
EGR Electronic Vacuum Regulator Solenoid: Specifications

EGR Vacuum Regulator Solenoid Nut ................................................................................................................................
> Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications > Page 4024
EGR Electronic Vacuum Regulator Solenoid: Service and Repair
5-7 Nm (40-61 lb in)1. Disconnect fuel charging wiring from EGR vacuum regulator solenoid.2. Disconnect main em
> Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications
EGR Tube: Specifications
EGR Valve Tube to Manifold Connector ............................................................................................................................

> Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 4028
EGR Tube: Service and Repair

REMOVAL
1. Remove air cleaner outlet tube.2. Raise vehicle on hoist.3. Disconnect EGR valve to exhaust manifold tube and EG
CAUTION: Use care not to damage EGR valve tube to manifold connector.
NOTE: Hold EGR valve tube to manifold connector with a wrench while disconnecting EGR valve to exhaust m
4. Lower vehicle.5. Disconnect EGR differential pressure transducer hoses from EGR valve to exhaust manifold tube
INSTALLATION
1. Position EGR valve to exhaust manifold tube into EGR valve and loosely connect EGR valve to exhaust manifold
NOTE: Do not tighten EGR valve to exhaust manifold tube nut on EGR valve at this time.
35-452. Connect EGR differential pressure transducer hoses to EGR valve to exhaust manifold tube.3. Raise vehicle.
Nm (26-33 lb-ft).
NOTE: Hold EGR valve tube to manifold connector with a wrench while tightening EGR valve to exhaust mani
5. Lower vehicle.
> Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 4029

> Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications
EGR Valve: Specifications
EGR Valve to Intake Manifold Bolts ...................................................................................................................................
(*) After tightening to 18-22 Nm (14-16 Lb/Ft), rotate an additional 85-95 degrees.
> Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 4033
EGR Valve: Service and Repair

REMOVAL
1. Remove air cleaner outlet tube.2. Disconnect EGR valve to exhaust manifold tube from EGR valve.
CAUTION: Use care not to damage EGR valve to exhaust manifold tube.
3. Disconnect vacuum hose from EGR valve.4. Remove two retaining bolts, EGR valve and EGR valve gasket from
INSTALLATION
18-22 Nm (14-16 lb-ft) 85-95 degrees

35-45 Nm (26-33 lb-ft)
1. Clean intake manifold sealing surface with a plastic-tipped scraper to remove any residual EGR valve gasket mate
> Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications

> Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4037

Engine View
> Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4038
> Powertrain Management > Emission Control Systems > Fillpipe Restrictor > Component Information > Description and Operation
Fillpipe Restrictor: Description and Operation

-
The restricted opening of the fuel tank filler pipe allows only a non-leaded fuel nozzle to be inserted. The restrict
-
Restricted fuel tank filler pipes are manufactured as an assembly, and must be serviced by removal and replacem
- Fuel tank filler pipes are not to be modified in any way.
> Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair > Crankcase Ventilation Hose
PCV Valve Hose: Service and RepairCrankcase Ventilation Hose
PCV Valve And Related Components
PCV
1. Remove air cleaner outlet tube.2. Disconnect crankcase vent connector and hose from Positive Crankcase Ventilat
> Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair > Crankcase Ventilation Hose >
PCV Valve Hose: Service and RepairCrankcase Ventilation Tube
1. Remove air cleaner outlet tube.2. Remove crankcase ventilation hose from LH valve cover grommet.3. Inspect gro
> Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Testing and Inspection
Positive Crankcase Ventilation Valve: Testing and Inspection

PCV
Cleaning of the Positive Crankcase Ventilation valve ( valve) is not recommended. The valve should be replaced at the
> Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Testing and Inspection > Page
Positive Crankcase Ventilation Valve: Service and Repair
PCV Valve And Related Components
1. Remove air cleaner outlet tube.2. Disconnect crankcase vent connector and hose from positive crankcase ventilatio
> Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specific


Engine View
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 4063

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 4064

REMOVAL
INSTALLATION
7.75 Nm (68 lb in)
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions
NOTE
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 4068
Fuel Pressure Gauge
Special Tool(s)
> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications

Hot Idle ................................................................................................................................................................................
> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 4072

> Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications
Accelerator Pedal: Specifications

Accelerator Pedal and Shaft To Dash Panel Nuts ................................................................................................................
> 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. Visually inspect the accelerator pedal and shaft and accelerator cable for customer's concern.2. If a cause for the re
> Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 40
Accelerator Pedal: Symptom Related Diagnostic Procedures
Before using the Symptom Chart:

- disconnect the accelerator cable from the throttle body lever.
- disconnect the speed control actuator cable (if equipped) from the throttle body.
> Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 40
Accelerator Pedal: Pinpoint Tests
A1-A2
B1-B3
> Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Page 4080
Accelerator Pedal: Service and Repair

REMOVAL
1. Push the accelerator cable nylon bushing out of the accelerator pedal arm.2. Remove the two accelerator pedal and
INSTALLATION
15-20 Nm (11-14 lb-ft)1. Follow removal procedure in reverse order.2. Tighten the accelerator pedal and shaft retain
> Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation

-
> Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation > Page 4085

> Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation > Page 4086
REMOVAL
INSTALLATION
> Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sens
Lean Driveability Symptoms
Article No.98-23-10
11/23/98
SERVICE TIP

> Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air

voltage at idle.
NOTE
Symptoms
^ Lack of Power
^ Buck/Jerk
OBDII DTCs
OBDI DTCs
NOTE:
> Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air

1.
NOTE
NOTE
2.
3.
4.
NOTE
> Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flo
98 > Engine - Lean Driveability Symptoms
Article No.98-23-10
11/23/98
SERVICE TIP

> Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service

voltage at idle.
NOTE
Symptoms
^ Lack of Power
^ Buck/Jerk
OBDII DTCs
OBDI DTCs
NOTE:
> Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service

1.
NOTE
NOTE
2.
3.
4.
NOTE
> Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4104


Engine View


- (PCM)

CAUTION:
> Powertrain Management > Fuel Delivery and Air Induction > Fillpipe Restrictor > Component Information > Description and Operation
Fillpipe Restrictor: Description and Operation

-
The restricted opening of the fuel tank filler pipe allows only a non-leaded fuel nozzle to be inserted. The restrict
-
Restricted fuel tank filler pipes are manufactured as an assembly, and must be serviced by removal and replacem
- Fuel tank filler pipes are not to be modified in any way.
> Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - Volatility Related Driveability Concerns
Fuel: Technical Service BulletinsFuel - Volatility Related Driveability Concerns
Article No.98-26-2
01/04/99
FUEL - INFORMATION ON GASOLINE - TIPS TORESOLVE VOLATILITY RELATED DRIVEABILITYCONCE
FORD:1985-97 THUNDERBIRD1986-99 MUSTANG, TAURUS1987-99 ESCORT1988-94 TEMPO1989-97 PROBE
LINCOLN-MERCURY:1985-97 COUGAR1986-92 MARK VII1986-99 SABLE1987-89 TRACER1988-94 TOPAZ1
LIGHT TRUCK:1986-97 AEROSTAR1987-96 BRONCO1989-97 F SUPER DUTY, F-3501989-99 F-150, F-250 LD,
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.
ISSUESome vehicles using winter blend fuels may exhibit a stall on start up and a no restart, hard start condition or a n
ACTIONRefer to the following text for further information.
NOTE
FUEL TANK ADDITIVES WILL NOT RESOLVE THESE CONCERNS BECAUSE VAPOR FORMS FROM CA
> Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - Volatility Related Driveability Concerns
> Page 4116

FILLING THE TANK TO FULL MAY BE EFFECTIVE. ADVISE CUSTOMER TO USE THE RECOMMENDED O
Explain to the customer that this concern may be due to a low tank level of winter blend fuel combined with unseasona
BACKGROUNDGasolines are seasonally adjusted, meaning they have higher volatility (vaporize easier) in the winter
Gasoline distribution practices often do not allow branded marketers to have much control over their gasoline's volatili
OTHER APPLICABLE ARTICLES: 91-8-13
SUPERSEDES: 96-5-4
OASIS CODES:402000, 404000, 602300, 603300,
607000, 607400, 608000, 608400, 609000, 609400, 610000, 611000, 611500, 612000, 614000, 614500
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 >
DTC's Stored/Check Fuel Cap Lamp ON
Fuel Filler Cap: Customer InterestEmissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
Article No.03-20-3
10/13/03

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler
Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4125

SERVICE PROCEDURE
NOTE
NOTE

NOTE


3.
5.
1.
4.

WARNING
NOTE
SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOC
6.
7.
8.
2.
3.
NOTE

6.
a.
11.
12.
Disclaimer
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap
MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
Fuel Filler Cap: All Technical Service BulletinsEmissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
Article No.03-20-3
10/13/03

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4135

SERVICE PROCEDURE
NOTE
NOTE

NOTE


3.
5.
1.
4.

WARNING
NOTE
6.
7.
8.
2.
3.
NOTE

6.
a.
11.
12.
Disclaimer
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Page 4140
Fuel Filler Cap: Description and Operation

The fuel tank filler cap is a sealed cap with a built-in pressure-vacuum relief valve::
- 2 kPa (0.28 psi)fuel system vacuum relief is provided after negative .
- 14 kPa (2 psi)provides pressure relief above .
-
under normal operating conditions, operates as a check valve, allowing air to enter the fuel tank as fuel is used wh
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions
NOTE
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 4145
Fuel Pressure Gauge
Special Tool(s)
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Specifications
Fuel Injector Wiring Harness: Specifications

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Specifications > Page 4150
Fuel Injector Wiring Harness: Description and Operation

The fuel charging wiring:
- TP
IACconnects the engine control sensor wiring to each fuel injector and other electronic engine controls such as T
- (PCM)receives fuel injector signals from the Powertrain Control Module and transfers the signals to the fuel inje
- on natural gas engines, the fuel injector signals are sent to the fuel injectors through the fuel injector driver modu
The signals from the powertrain control module determine the fuel injection sequence and duration each fuel injector w
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Specifications > Page 4151
Fuel Injector Wiring Harness: Service and Repair

8-12 Nm (71-106 lb in)1. Disconnect battery ground cable.2. Remove air cleaner outlet tube from throttle body.3. D
2.5-3.2 Nm (23-28 lb in)clamp to . Verify all electrical connections.
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Spring Lock Coupling
Fuel Line Coupler: Description and OperationSpring Lock Coupling

Spring lock couplings are used to connect the fuel tubes to the engine fuel rails.
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Spring Lock Coupling > Page 4156
Fuel Line Coupler: Description and OperationPush Connect Fitting

4.6L (MFI)Steel fuel tubes and rubber-covered nylon fuel hose assemblies with push connect fittings are used with M
Nylon push connect fittings are used to make the fuel line connections to the fuel filter and base. Steel push connect fitt
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Coupling
Fuel Line Coupler: Service and RepairSpring Lock Coupling

WARNING:
-
DO NOT SMOKE, CARRY LIGHTED TOBACCO OR AN OPEN FLAME OF ANY TYPE WHEN WOR
-
FUEL SUPPLY LINES ON VEHICLES EQUIPPED WITH FUEL INJECTED ENGINES WILL REMAI
REMOVAL
Fuel Tube Clip
1. Remove clip from spring lock coupling.
1/2 inch2. Position Spring Lock Coupling Disconnect Tool 310-D004 (D87L-9280-A) for 3/8 inch tube or 310-D005
equivalent onto coupling. Make sure that tool can enter cage opening to release the garter spring.
3. Push the spring lock coupling disconnect tool into the cage opening to release the female fitting from the garter sp
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Coupling > Page 4159

4. Pull the coupling male and female fittings apart.
5. Remove the spring lock coupling disconnect tool from the disconnected spring lock coupling.
6. Clean fittings with solvent.
NOTE: Inspect coupling for missing or damaged
O-rings. If either O-ring is damaged both O-rings must be replaced. Replace 0-rings or garter springs with the appropri
INSTALLATION
1. Lubricate the 0-rings with clean engine oil.
Garter Spring
2. Insert male fitting into female fitting and push together until garter spring is engaged.3. Pull on fittings to ensure c

4. Install clip to spring lock coupling.
5. Make sure clip is correctly installed.

Fuel Line Coupler: Service and RepairSteel Push Connect Fittings
WARNING: FUEL SUPPLY TUBES ON VEHICLES EQUIPPED WITH FUEL INJECTED ENGINES WILL
Description
- Fuel Line Disconnect Tool (5/16 Inch)
- Fuel Line Disconnect Tool (3/8 Inch)
Tool Number
- 310-040 (T90T-9550-B) (Part of 310-8039 (T90T-9550-S))
- 310-041 (T90T-9550-C) (Part of 310-8039 (T90T-9550-S))
This fitting consists of a body, spacers, O-rings and a retaining clip. The clip locks the fitting to its mating tube juncture
Before attempting to disconnect the fitting:
1. Inspect visible internal portion of fitting for dirt accumulation. Clean the fitting before disassembly.2. Some adhes
fitting until it moves freely on the tube.
NOTE: If necessary, drain fuel tank.
REMOVAL
5/16-inch1. To disengage the tube from the fitting, snap the Fuel Line Disconnect Tool 310-040 (T90T-9550-B) (Gr
3/8-inch(T90T-9550-C) (Blue) (Part of 310-5039 (T90T-9550-S)) with either tab on the fuel line to be disconnec
2. Push the disconnect tool into the connector to release the internal locking fingers.
NOTE: Some fuel tubes have a secondary bead which aligns with the outer surface of the clip. These beads can
3. Separate fuel tube from the connector. Remove disconnect tool.

NOTE: Only moderate effort is required if the tube has been properly disengaged. Use hands only.
4. After disassembly, inspect and clean the tube end sealing surface. Tube end should be free of scratches and corros
fitting for any internal parts such as O-rings and spacers that may have been dislodged from the fitting. Replace a
INSTALLATION
1. Install new connector/hose tube assembly if damage was found.2. Before installing fitting on the tube, wipe tube e
click will be heard. Pull on fitting to verify it is fully engaged. Applying a light coat of clean engine oil meeting F
Fuel Line Coupler: Service and RepairNylon Push Connect Fittings
WARNING: FUEL SUPPLY TUBES ON VEHICLES EQUIPPED WITH FUEL INJECTED ENGINES WILL
3/8-inch 5/16-inchPush connect fittings used to connect to and nominal diameter metal tubing use a hairpin clip.
Disconnect all push connect fittings from components (sender, filter) prior to component removal. The push connect fit
REMOVAL
1. Inspect visible internal portion of fitting for dirt accumulation. If more than a light coating of dust is present, clean
NOTE: If necessary, drain fuel tank.
2. Some adhesion between the seals in the fitting and the tubing will occur with time. To separate, twist the fitting on
fitting until it moves freely on the tube.
NOTE: 90 degree On elbow connectors, excessive side loading could break the connector body.
3. Remove hairpin clip from fitting by first bending the shipping tab downward so that it will clear the body. Next, (u
3.2 mm (1/8 inch)
clip legs about each to disengage the body and push the legs into the fitting. Complete removal is accomplished
CAUTION: Do not use any tools.
4. Grasp the fitting and hose assembly and pull in an axial direction to remove the fitting from the steel tube.5. When
loose internal parts should be immediately installed, using the mating tube to insert the parts.
INSTALLATION
1. It is recommended that the original clip not be reused in the fitting. To install the new clip, insert clip into any two
triangular portion pointing away from the fitting opening. Install clip to fully engage the body (legs of hairpin cli
2. Before installing fitting on the tube, wipe tube end with a clean cloth. Inspect the inside of the fitting to ensure it is
click will be heard. Pull on fitting to ensure it is fully engaged. Applying a tight coat of clean engine oil meeting
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications
Fuel Pressure Regulator: Specifications

Fuel Pressure Regulator .......................................................................................................................................................
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 4166
Fuel Pressure Regulator: Description and Operation

The fuel pressure regulator:
- is mounted on the fuel injection supply manifold downstream of the fuel injectors.
- regulates the fuel pressure supplied to the fuel injectors.
-
is anominal fuel pressurerelief

diaphragm-operated is established by a spring
valve in which preload
one side of theapplied to thesenses
diaphragm diaphragm.
fuel pressure and the other side is
- balances one side of the diaphragm with manifold pressure to maintain a constant fuel pressure drop across the fu
- bypasses and returns excess fuel to the fuel tank.
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 4167
Fuel Pressure Regulator: Service and Repair

Description
- Spark Plug Wire Remover
Tool Number
- T74P-6666-A
REMOVAL
1. Perform Fuel Charging System Pre-Service and Fuel Pressure Release procedures if removing fuel pressure regula
manifold is installed on engine.
2. Remove air cleaner outlet tube from throttle body.3. Remove vacuum line at fuel pressure regulator.4. Remove the
INSTALLATION
1. Lubricate new fuel pressure regulator O-rings with clean engine oil XO-10W30-QSP or -DSP or equivalent meetin
WSS-M2C153-G.
CAUTION: Never use silicone grease. It will clog the fuel injectors.
2.5-3.2 Nm (22-28 lb in)

2. Make sure sealing surfaces of fuel pressure regulator and fuel injection supply manifold are clean.3. Using new re
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Specifications

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Specifications > Page 4171

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Specifications > Page 4172

REMOVAL
INSTALLATION
7.75 Nm (68 lb in)
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 4178

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 4179

REMOVAL
INSTALLATION
7.75 Nm (68 lb in)
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations

Engine View
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4183

Relay Center (C110)
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Page 4186

> Page 4187

System Diagrams
> Page 4188

Grounds Diagrams
> Page 4189

ELECTRICAL SYMBOLS
Electrical Symbols
> Page 4190

Electrical Symbols
VACUUM SYMBOLS
> Page 4191

Vacuum Symbols

BK
BL
BR
> Page 4192

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 4193

(PCM)
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 4194
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications
Fuel Rail: Specifications

Fuel Injection Supply Manifold Retaining Bolts .............................................................................................................
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 4198
Fuel Rail: Description and Operation
The fuel injection supply manifold delivers high-pressure fuel from the vehicle fuel supply line to the eight fuel injecto
- tubular fuel rail
- eight fuel injector connectors
- a mounting flange to the fuel pressure regulator
- mounting attachments which locate the fuel injection supply manifold and provide fuel injection retention
- fuel inlet and outlet connections which have push-connect fittings
Fuel Rail: Service and Repair
REMOVAL
(3/8 inch) (1/2 inch)1. Perform Pre-Service and Fuel Pressure Release procedure.2. Remove air cleaner outlet tube f
Useand
supply specified
return tool
linesorfrom
equivalent.
the fuel injection supply manifold.-
- Inspect for missing or damaged O-rings.
- Use the specified fuel resistant O-rings (brown).
- Lubricate the O-ring with clean engine oil.
- Make sure that the fitting is locked.
NOTE: The following items should be noted when service is required:

6. Disconnect fuel charging wiring from fuel injectors.7. Remove four fuel injection supply manifold retaining bolts.
NOTE: It may be easier to remove fuel injectors with the fuel injection supply manifold as an assembly.
9. Use a rocking, side-to-side motion while lifting to remove fuel injectors from fuel injection supply manifold.
INSTALLATION
1. Push fuel injection supply manifold down to make sure all fuel injector O-rings are fully seated in the fuel injectio
intake manifold.

CAUTION:
When installing fuel injection supply manifold make sure that the fuel injector O-rings are properly seated so th
8-12 Nm (71-106 lb in)
2.5-3.2 Nm (23-28 lb in)

2. Install retaining bolts while holding down fuel injection supply manifold. Tighten retaining bolts to .3. Install sprin
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair
Fuel Return Line: Service and Repair
WARNING: FUEL SUPPLY LINES ON ALL VEHICLES EQUIPPED WITH FUEL INJECTED ENGINES W
Fuel lines are not repairable and must be replaced if damaged. Repair may not comply with Clean Air Act regulations.
The individual stainless steel tubes of the fuel and vapor return tube are secured together by the manufacturer and are s
CAUTION:
The nylon fuel lines can be damaged by torches, welding sparks, grinding and other operations which involve heat and
- Exhaust or suspension components in proximity to fuel tubes.
- Floor pan under vehicle and inside the passenger compartment (RH side).
- Rocker panel (RH side).
- Underbody frames, rails and crossmembers (RH side).
- Dash panel, under vehicle or inside the passenger compartment (lower RH side).
- Front or rear wheel house/fender apron (RH side).
REMOVAL
1. Relieve fuel system pressure.2. Drain fuel from fuel tank.3. Raise vehicle on hoist.4. Lower fuel tank and disconne
INSTALLATION
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair
Fuel Supply Line: Service and Repair
WARNING: FUEL SUPPLY LINES ON ALL VEHICLES EQUIPPED WITH FUEL INJECTED ENGINES W
Fuel lines are not repairable and must be replaced if damaged. Repair may not comply with Clean Air Act regulations.
The individual stainless steel tubes of the fuel and vapor return tube are secured together by the manufacturer and are s
CAUTION:
The nylon fuel lines can be damaged by torches, welding sparks, grinding and other operations which involve heat and
- Exhaust or suspension components in proximity to fuel tubes.
- Floor pan under vehicle and inside the passenger compartment (RH side).
- Rocker panel (RH side).
- Underbody frames, rails and crossmembers (RH side).
- Dash panel, under vehicle or inside the passenger compartment (lower RH side).
- Front or rear wheel house/fender apron (RH side).
REMOVAL
1. Relieve fuel system pressure.2. Drain fuel from fuel tank.3. Raise vehicle on hoist.4. Lower fuel tank and disconne
INSTALLATION
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct >
Stored/Check Fuel Cap Lamp ON
Fuel Filler Hose: Customer InterestEmissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
Article No.03-20-3
10/13/03

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest: >
03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4216

SERVICE PROCEDURE
NOTE
NOTE

NOTE


3.
5.
1.
4.

WARNING
NOTE
6.
7.
8.
2.
3.
NOTE

6.
a.
11.
12.
Disclaimer
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03
ON/DTC's Stored/Check Fuel Cap Lamp ON
Fuel Filler Hose: All Technical Service BulletinsEmissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
Article No.03-20-3
10/13/03

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > 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 4226

SERVICE PROCEDURE
NOTE
NOTE

NOTE


3.
5.
1.
4.

WARNING
NOTE
6.
7.
8.
2.
3.
NOTE

6.
a.
11.
12.
Disclaimer
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel F
Feb > 08 > Recall 08V051000: Incorrect Speed Control Jumper Harness
Wiring Harness: All Technical Service BulletinsRecall 08V051000: Incorrect Speed Control Jumper Harness
MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria
Lincoln/Town Car 1992-1995 Mercury/Grand Marquis 1992-1998 MANUFACTURER: Ford Motor Comp
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 Cr
CONSEQUENCE: As a result, the fuse is located in the output circuit rather than in the intended input power feed circ
REMEDY: Dealers will install a new wiring harness, or replace the mating electrical component. The recall is expecte
NOTES: Ford recall No. 08S01. Customers may also contact The National Highway Traffic Safety Administration's V
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Fuel Filler Hose: > NHTSA08V051000 > Feb > 08 > Recall 08V051000: Incorrect Speed Control Jumper Harness > Page 4236

(TTY 1-800-424-9153), or go to http://www.safercar.gov.
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Fuel Filler Hose: > NHTSA08V051000 > Feb > 08 > Recall 08V051000: Incorrect Speed Control Jumper Harness > Page 4242

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4243
Fuel Filler Hose: Service and Repair
WARNING: DO NOT SMOKE, CARRY LIGHTED TOBACCO OR AN OPEN FLAME OF ANY TYPE WHE
REMOVAL
1. Drain fuel tank. Make sure vehicle has less than 3/4 tank of fuel.2. Remove four screws from the fuel filler housin
10. Rotate the fuel tank filler pipe and remove through the wheel opening.11. Remove and discard filler pipe gromme
INSTALLATION
1. Lubricate a new fuel tank grommet with clean engine oil meeting Ford specification WSS-M2C153-G.2. Slide the
NOTE: Make sure that the fuel tank filler pipe retainer is positioned between the locating beads on the fuel tank
2.3-3.3 Nm (21-29 lb in)

6.8-9.2 Nm (61-81 lb in)
3. Rotate the fuel tank filler pipe into position with the fuel filler housing.4. Install four retaining screws for fuel tank
to 2.3-3.3 Nm (21-29 lb in)10. Install four fuel filler housing retaining screws. Tighten .
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Nec
MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
Fuel Filler Neck: Customer InterestEmissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
Article No.03-20-3
10/13/03

> 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 4252

SERVICE PROCEDURE
NOTE
NOTE

NOTE


3.
5.
1.
4.

WARNING
NOTE
6.
7.
8.
2.
3.
NOTE

6.
a.
11.
12.
Disclaimer
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for F
> Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
Fuel Filler Neck: All Technical Service BulletinsEmissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
Article No.03-20-3
10/13/03

> 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 4262

SERVICE PROCEDURE
NOTE
NOTE

NOTE


3.
5.
1.
4.

WARNING
NOTE
6.
7.
8.
2.
3.
NOTE

6.
a.
11.
12.
Disclaimer
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Electronic Instrument Cluster

Fuel Level Sender
TheWhen the fuelof
the level is low
of an and number
attached of litfuel
tank.-
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Electronic Instrument Cluster > Pag
NOTE:
Theislow
designed to reduce
fuel level fuel
switch:-
Fuel Pump Module

TheAfuel
variable
pumpresistor
moduleisconsists
-
-
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Specifications
Fuel Tank Mounting Straps: Specifications

Fuel Tank Support Strap Retaining Nuts .............................................................................................................................
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Specifications > Page 4275
Fuel Tank Mounting Straps: Service and Repair

REMOVAL
1. Place support under fuel tank.
NOTE:
Either fuel tank support strap may be removed without removing fuel tank if a support is provided under the fuel
2. Push the strap to be removed into the body bracket until the pin aligns with large hole in body bracket.3. Push the
INSTALLATION
30-40 Nm (23-29 lb-ft)

1. Follow removal procedure in reverse order.2. Install new fuel tank mounting strap studs.3. Tighten retaining nuts t
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Service and Repair

WARNING:
-
-
-M2C153-G.
> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator - Electronic > Component Information > Specifications
Idle Speed/Throttle Actuator - Electronic: Specifications

Idle Air Control Valve to Intake Manifold Bolts .................................................................................................................
(*) Tighten to 8-10 Nm (71-88 lb in), then rotate bolts 85-95 degrees.
> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator - Electronic > Component Information > Specifications > Page 4282
Idle Speed/Throttle Actuator - Electronic: Service Precautions

CAUTION:
Do not use Carburetor Tune-Up Cleaner D9AZ-19579-BA meeting Ford specification ESR-M14P9-A or any other typ
IACThe Idle Air Control valve ( valve) cannot be cleaned. It must be replaced.
> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator - Electronic > Component Information > Specifications > Page 4283
Idle Speed/Throttle Actuator - Electronic: Description and Operation
IAC
(PCM)The Idle Air Control valve ( valve) controls engine idle speed. The idle air control valve is mounted on the intak
> Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch
Inertia Switch Bracket Replacement

99B03
Dealer Letter
Administrative
^ Refund Codes
Labor Allowances
Attachment II^
TechnicalIII^

> Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Recalls for Inertia Fuel
Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4292


PROMPTLY CORRECT


LABOR ALLOWANCES
PARTS REQUIREMENTS
CLAIMS PREPARATION

SERVICE PROCEDURE
1. Open trunk.



5.




20. Close trunk.




> Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ine
Mar > 99 > Campaign - Inertia Switch Bracket Replacement

99B03
Dealer Letter
Administrative
^ Refund Codes
Labor Allowances
Attachment II^
TechnicalIII^

> Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4307


PROMPTLY CORRECT


LABOR ALLOWANCES
PARTS REQUIREMENTS
CLAIMS PREPARATION

SERVICE PROCEDURE
1. Open trunk.



5.




20. Close trunk.




> Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical Service Bulletins > Page 4317
> Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Diagrams > Diagram Information and Instructions >
Page 4320

Page 4321

System Diagrams
Page 4322

Grounds Diagrams
Page 4323

ELECTRICAL SYMBOLS
Electrical Symbols
Page 4324

Electrical Symbols
VACUUM SYMBOLS
Page 4325

Vacuum Symbols

BK
BL
BR
Page 4326

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Diagrams > Page 4327
(IFS)
> Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Diagrams > Page 4328
REMOVAL
IFS
INSTALLATION
> Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair
Intake Air Duct: Service and Repair

REMOVAL
1. Loosen engine air cleaner intake collars.2. Disconnect crankcase ventilation tube and idle air control valve inlet tu
INSTALLATION
3.4-4.6 Nm (30-40 lb in)1. Follow the removal procedure in reverse order.2. Tighten engine air cleaner tube clamps
> Powertrain Management > Fuel Delivery and Air Induction > Integrated Control Relay Module > Component Information > Diagrams
Relay Center (C110)

> Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations

Engine View
> Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4338

Relay Center (C110)
> Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations

Engine View
> Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information >

Relay Center (C110)
> Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram

- System Diagrams
- Grounds Diagrams


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 435

(PCM)
> Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 435
> Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Integrated Control Relay Module > Component Information > Diagr
Relay Center (C110)

> Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Lo

Engine View
> Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component

Relay Center (C110)
> Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Serv
Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms
Article No.98-23-10
11/23/98
SERVICE TIP

> 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 for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4371

voltage at idle.
NOTE
Symptoms
^ Lack of Power
^ Buck/Jerk
OBDII DTCs
OBDI DTCs
NOTE:
Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4372

1.
NOTE
NOTE
2.
3.
4.
NOTE
Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms
Article No.98-23-10
11/23/98
SERVICE TIP

Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4378

voltage at idle.
NOTE
Symptoms
^ Lack of Power
^ Buck/Jerk
OBDII DTCs
OBDI DTCs
NOTE:
Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4379

1.
NOTE
NOTE
2.
3.
4.
NOTE


Engine View


- (PCM)

CAUTION:
> Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Service and

WARNING:
-
-
-M2C153-G.
> Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Technical
Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement

99B03
Dealer Letter
Administrative
^ Refund Codes
Labor Allowances
Attachment II^
TechnicalIII^

> Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component
Information > Technical Service Bulletins > Recalls for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement > Page 4396


PROMPTLY CORRECT


LABOR ALLOWANCES
PARTS REQUIREMENTS
CLAIMS PREPARATION

SERVICE PROCEDURE
1. Open trunk.



5.




20. Close trunk.




Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket Replacement

99B03
Dealer Letter
Administrative
^ Refund Codes
Labor Allowances
Attachment II^
TechnicalIII^

Information > Technical Service Bulletins > All Technical Service Bulletins for Inertia Fuel Shutoff Switch: > 99B03 > Mar > 99 > Campaign - Inertia Switch Bracket
Replacement > Page 4411


PROMPTLY CORRECT


LABOR ALLOWANCES
PARTS REQUIREMENTS
CLAIMS PREPARATION

SERVICE PROCEDURE
1. Open trunk.



5.




20. Close trunk.




> Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Diagrams
Instructions

- System Diagrams
- Grounds Diagrams


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
(IFS)
REMOVAL
IFS
INSTALLATION
> Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specification




TP
> Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications
Throttle Body: Specifications

Throttle Body and Adapter Bolts .....................................................................................................................................
> Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 4443
Throttle Body: Description and Operation

The throttle body functions as follows:
-
The(WOT)
throttleAbody
cam provides
lever andcontrol
accelerator
of engine
cableairflow.-
rotates the throttle shaft from idle to Wide Open Throttle position.
-
The plate position at idle is factory set by the lever contacting a throttle return control screw. The head of the
- IAC
Throttle body idle airflow provides minimum engine airflow while the Idle Air Control valve ( valve) provide
Other features of the throttle body include:

- the WOT-plate position which is obtained when the lever contacts the throttle body casting.
- TP (PCM)Throttle Position sensor ( sensor) which provides an electrical signal which is used as an input to the P
-
a sealant which is applied to the downstream side of the throttle body plate and bore to reduce plate to bore leaka
Throttle Body: Testing and Inspection
WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHE
The throttle body for this vehicle is a sludge-resistant design with a coating on the bore and plate. Sludge accumulation
Throttle Body: Adjustments

Throttle Body: Service and Repair
REMOVAL
TP
1. Remove air cleaner outlet tube from throttle body.2. Disconnect Throttle Position sensor ( sensor) from fuel charg
INSTALLATION
1. Clean gasket mating surfaces.
NOTE: If scraping is necessary, do not damage gasket surfaces or allow material to drop into manifold.
8-12 Nm2. Install throttle body, new throttle body gasket and four bolts to the throttle body to intake manifold space
(71-106 lb in).
2.5-3.2 Nm (23-28 lb in)3. Connect throttle position sensor to fuel charging wiring and accelerator cable at the thrott
> Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications
Throttle Cable/Linkage: Specifications
Accelerator Cable Bracket To Intake Manifold Bolts .........................................................................................................

> 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. Visually inspect the accelerator pedal and shaft and accelerator cable for customer's concern.2. If a cause for the re
> Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Pa
Throttle Cable/Linkage: Symptom Related Diagnostic Procedures
Before using the Symptom Chart:

- disconnect the accelerator cable from the throttle body lever.
- disconnect the speed control actuator cable (if equipped) from the throttle body.
> Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Pa
Throttle Cable/Linkage: Pinpoint Tests
A1-A2
B1-B3
> Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Testing and Inspection > Page 4454
Throttle Cable/Linkage: Service and Repair

REMOVAL
1. Push the accelerator cable nylon bushing out of the accelerator pedal and shaft arm.2. Remove the accelerator cabl
accelerator cable housing passes through the dash panel into the passenger compartment.
(WOT)3. Disconnect the accelerator cable at the throttle body lever by rotating the throttle lever to the Wide Open T
cable through the slot in the throttle body lever cam.
4. Remove the accelerator cable housing to the accelerator cable bracket retaining screw.5. Remove the accelerator c
INSTALLATION
6.35 mm (1/4 inch)

8-12 Nm (71-106 lb in)1. Follow removal procedure in reverse order.2. Make sure the accelerator cable retainer is p
cable moves freely.
> Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications

> Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 4458



TP
> Powertrain Management > Ignition System > Firing Order > Component Information > Specifications
Firing Order 1-3-7-2-6-5-4-8
Coil On Plug
> Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations
> Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications

> Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 4473


REMOVAL
CMP
INSTALLATION
sensor.
> Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications

> Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4479

Engine View

CKP
REMOVAL
CKP
INSTALLATION
position sensor.
> Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips
Ignition Coil: Technical Service BulletinsIgnition 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 ORROUG
FORD:1996-1999 Taurus SHO1998-2006 Crown Victoria, Mustang2000 Taurus2002-2005 Thunderbird2003-2006 Fo
MERCURY:1998-2006 Grand Marquis2000 Sable2004-2005 Sable2005-2006 Montego2002-2005 Mountaineer2005-2

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 F
ISSUEApproximately 50% of coil on plug (COP) coils returned for warranty do not have a problem.
ACTIONThe misfiring cylinder must be identified through Self-Test misfire codes or through WDS Power Balance. Ru
SERVICE PROCEDURE
The optional WDS COP Kit available through Rotunda will provide more accurate diagnosis and help reduce replacem
The following material will detail the diagnostic steps on WDS to take the guesswork out of misfire diagnosis using the
> Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic
Tips > Page 4487

Misfire Definition: A misfiring cylinder is lacking power relative to the other cylinders. The causes for a cylinder speci
Perform a thorough visual inspection. If no visible concerns are found use the following WDS tools for misfire diagnos
^ 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 I
If there is a self-test code identifying a particular cylinder then you just need to determine if it is a fuel, ignition, or
Step 1: (Select Toolbox Icon, then Powertrain, then Power Balance)

Tips > Page 4488

The cylinder specific miss has to be identified as shown in the example in Figure 2 in order to proceed with the remaini
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
Tips > Page 4489

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 kilov
NOTE
LIVE DISPLAY HAS TO AVERAGE IGNITION VALUES BECAUSE THERE IS TOO MUCH DATA TO DISP
Tips > Page 4490

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 Bl
Step 4: (Select Toolbox, then Oscilloscope)
WARNING
SECONDARY IGNITION VOLTAGES ARE VERY HIGH. KEEP HANDS AND TOOLS AWAY FROM THE E
SET-UP: With the engine off, pull the suspect coil from the cylinder well and turn it upside down so the coil cannot spa
CAUTION
THE COIL BOOT CAN BE DAMAGED IF THE COIL SPARKS TO ANOTHER SURFACE DURING THIS PR
Keep the coil connected to the harness and leave the WDS COP clip attached to the coil. Route the coil clip wire and ca
COP Stress Test Procedure:
Tips > Page 4491

Tips > Page 4492

Go to the Oscilloscope Tool and select Channel 3, then select Auto, then select COP_STRESS_TEST_RED. This pre-c
Figure 8 and Figure 9 are examples of problem coils. Replace the coil if the waveform is similar to Figures 8 or 9. The
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
OTHER APPLICABLE ARTICLES: 05-13-4
Disclaimer
> Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 4493
Ignition Coil: Specifications

Coil Per Plug Retaining Bolts ..............................................................................................................................................
Ignition Coil: Diagrams
Firing Order 1-3-7-2-6-5-4-8
Coil On Plug
Ignition Coil: Description and Operation
(PCM)The engine uses eight separate coil per plug units. Each coil per plug unit is controlled by the Powertrain Contro
Each coil per plug unit is mounted directly above each spark plug and activates its own spark plug in the proper sequen
> Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Cleaning and Inspection
Ignition Coil: Service and RepairCleaning and Inspection

Inspect coil per plug unit for cracks, carbon tracking, dirt, or damage.
> Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Cleaning and Inspection > Page 4498
Ignition Coil: Service and RepairIgnition Coil-On-Plug (COP)

REMOVAL
1. Disconnect battery ground cable.2. Remove fuel rail.3. Disconnect engine control sensor wiring connector from co
INSTALLATION
8-12 Nm (71-106 lb in)
1. Install coil per plug unit and retaining bolts. Tighten bolts to .2. Connect engine control sensor wiring connectors t
> Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations

> Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 4502

PURPOSE
- (ICM) (PCM)
OPERATION
-
> Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations

> Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 4507

PURPOSE
- (ICM) (PCM)
OPERATION
-
> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications

> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 4512


REMOVAL
CMP
INSTALLATION
sensor.
> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications

> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4518

Engine View

CKP
REMOVAL
CKP
INSTALLATION
position sensor.
> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bu
Packages Available
Article No.99-24-2
11/29/99

> 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 4527


NOTE

^
^
NOTE

NOTE

NOTE
NOTE

> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair >

NOTE:
REMOVAL
drill.
INSTALLATION
> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair >
REMOVAL
INSTALLATION
> Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap
Spark Plug Gap .................................................................................................................................................................. 1

> Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap > Page 4539
Spark Plug Gap .................................................................................................................................................................. 1

> Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4540

Spark Plug Type ...................................................................................................................................................................




REMOVAL
INSTALLATION
> Powertrain Management > Transmission Control Systems > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Compone
Shift Interlock Solenoid: Specifications

Shift Lock Actuator Screw ..............................................................................................................................................
> Powertrain Management > Transmission Control Systems > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Compone
4551
Shift Interlock Solenoid: Service and Repair

REMOVAL
1. Disconnect battery ground cable.2. Remove screws and upper steering column shroud.3. Insert a scratch awl into t
pin, rotate the ignition lock cylinder clockwise to the RUN position and remove the ignition lock cylinder from th
4. Remove the lower steering column shroud.5. Remove two screws and knee bolster from instrument panel.6. Rotat
lever. After the shift indicator cable is disconnected, continue to rotate the shift indicator adjustment wheel clock
CAUTION:
Before lowering steering column tube, completely loosen the shift indicator adjustment mechanism and disconne
7. Remove two nuts and steering column absorber.8. Remove two nuts and lower steering column tube.9. Disconnec
10. Remove two Torx head screws and shift lock actuator from steering column tube.
INSTALLATION
2.0 Nm (18 inch lbs.)
13 - 17 Nm (10 - 12 ft. lbs.)
13 - 17 Nm (10 - 12 ft. lbs.)
1. Install shift lock actuator onto steering column tube and secure with two Torx head screws. Tighten screws to . 2.
Rotate the shift indicator adjustment wheel counterclockwise onto the shift indicator adjustment mechanism and
5. Install knee bolster to instrument panel and secure with two screws.6. Place lower steering column shroud into pos
transmission range selector lever should be locked in the PARK position with the key removed.
> Powertrain Management > Transmission Control Systems > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component In
Shift Solenoid: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.2. Raise vehicle on a hoist.3. Drain transmission fluid.
4. Remove 14 pan retaining bolts, transmission pan and pan to case gasket.
5. Remove pan magnet. Clean transmission pan and pan magnet.

6. Using both hands, remove filter by pulling downward.
CAUTION:
If installing a new filter, and grommet remains in the main control bore, carefully use a small screwdriver to rem
> Powertrain Management > Transmission Control Systems > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T >
Component Information > Service and Repair > Page 4555

NOTE:
If transmission is being serviced for a contamination-related failure, use a new filter and grommet. The filter ma
7. Remove one bolt retaining manual control valve detent lever spring to the main control valve body. Remove manu
spring.
8. Disconnect transmission shift linkage from manual control lever by removing the nut.
(TR)9. Remove two bolts retaining digital Transmission Range sensor to case. Remove digital transmission range se
10. Remove the EPC solenoid bracket retaining bolt. Remove the EPC solenoid bracket.
NOTE:
For clarity, the following illustrations show the main control valve body removed. It is not necessary to remove

11. Remove manual lever shaft retaining pin.
NOTE: Use a shop cloth to protect pan-to-case surface.
12. Using a 13/16 inch open-end wrench on the inner nut and a 12 mm wrench on the manual control lever shaft flats,
Slide manual control lever partially out of the case to complete removal of the inner nut from manual control-leve
13. Slide manual control lever out of case. Position manual valve detent lever so that EPC solenoid can be removed. R
by grasping connector body and pulling. Remove EPC solenoid by sliding it out of the case bore.
INSTALLATION

1. Lubricate EPC solenoid seal and wiring with a light coating of MERCON V Multi-Purpose Automatic Transmissi
MERCON V approved fluid. Install EPC solenoid by sliding it into the bore.
11 - 15 Nm (98 - 132 inch lbs.)
26 - 37 Nm (20 - 27 ft. lbs.)

2. Install the EPC solenoid bracket. Install bolt and tighten to . 3. Install connector to EPC solenoid by pushing conne

7 - 10 Nm (62 - 88 inch lbs.).

9 - 11 Nm (80 - 97 inch lbs.). 12 - 15 Nm (107 - 132 inch lbs.).10. Tighten digital TR sensor bolts to 11. Install manu
19 - 26 Nm (14 - 19 ft. lbs.).
13. Attach transmission linkage to manual control lever. Tighten adjusting nut to 14. Pour 4.7 liters (5 quarts) of MER
> Powertrain Management > Transmission Control Systems > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A
Specifications
Torque Converter Clutch Solenoid: Specifications

TCC Solenoid-to-Main Control ...........................................................................................................................................
> Powertrain Management > Transmission Control Systems > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information
Shift Indicator: Adjustments
1.4 kg (3 lbs.)
1. Remove instrument panel lower trim panel.2. Place transmission range selector lever in D position and hold lever
adjustment.
4. For the digital instrument cluster, align the indicator such that both calibration dots are white when parallel to the s
number in each position.
6. Install the instrument panel lower trim panel.
> Powertrain Management > Transmission Control Systems > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information
Shift Indicator: Service and Repair

REMOVAL
1. Remove instrument cluster.2. Remove eight screws from instrument cluster main lens and instrument cluster mask
INSTALLATION
1. Install control selector bracket and cable to speedometer and secure snaps.2. Install speedometer into the instrume
Install four cluster retaining screws.
6. Position transmission range indicator column bracket to steering column (locate pin in column slot) and adjust tran
follows:a. Place transmission selector lever arm and support on the steering column in the 1 position.b. Place loop
within the letter (D).
e. When properly adjusted, the entire width of pointer must fall within the width of the letter (D) and must touch
when viewed parallel to the center line of the steering column from the driver's position.
7. Position lower steering column shroud and install retaining screws.8. Connect battery ground cable.9. Check instru
> Powertrain Management > Transmission Control Systems > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Com
Repair > Disassembly and Assembly
Transmission Mode Indicator - A/T: Service and RepairDisassembly and Assembly

DISASSEMBLY
1. Disconnect battery ground cable.2. Set parking brake.3. Unsnap LH instrument panel moulding and RH instrumen
10. Remove instrument panel finish panel carefully so not to scratch the instrument cluster lens.11. Disconnect transm
forward.
12. Remove screw retaining control selector bracket and cable to steering column.13. Disconnect cable loop from gea
range indicator.
ASSEMBLY
1. Install transmission range indicator.2. Connect cable loop from gearshift lever pin to the transmission selector leve
Covering the calibration dots in the NEUTRAL or DRIVE (N or D) positions is acceptable.
8. Install instrument panel finish panel to place and connect electrical connectors to message center switch module.9.
10. Install knob to headlamp switch.11. Raise steering column and install four retaining nuts.12. Install instrument pan
> Powertrain Management > Transmission Control Systems > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Com
Repair > Disassembly and Assembly > Page 4572
Transmission Mode Indicator - A/T: Service and RepairTransmission Range Indicator

REMOVAL
INSTALLATION
> Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Informa
> Powertrain Management > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Control Switch <--> [Overd
Information > Description and Operation

(PCM)
(TCIL)
OPERATION
TheThe system
range engages
transmission mode
control switch each
in the time
shift theknob.-
-
> Powertrain Management > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Infor
> Customer Interest for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative
Article No.02-13-6
07/08/02
ISSUE
ACTION
Parts Block

BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
> Powertrain Management > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch >
Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page
4591

3.
> Powertrain Management > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Infor
> All Technical Service Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative
Article No.02-13-6
07/08/02
ISSUE
ACTION
Parts Block

BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
> Powertrain Management > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock -

3.
> Powertrain Management > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Compo

> Powertrain Management > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range (TR) Sensor <
Sensor, A/T] > Component Information > Locations
Transmission View

Sensor, A/T] > Component Information > Locations > Page 4604

7 - 10 Nm (62 - 88 inch lbs.).
19 - 26 Nm (14 - 19 ft. lbs.)
REMOVAL
INSTALLATION
(TR)
7 - 10 Nm (62-88 inch lbs.)
19 - 26 Nm (14 - 19 ft. lbs.)
> Powertrain Management > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Compo

Page 4611
Transmission View
Page 4612

Page 4613
REMOVAL
(VSS)
INSTALLATION
7 - 10 Nm (62 - 88 inch lbs.)

> Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 00-10-3 > May > 00 > PCM - Engi
Article No.00-10-3
05/15/00

DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100
> Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 00-10-3 > May > 00
> PCM - Engine Spark Knock While Accelerating > Page 4622

Service Procedure
4. Select PCM.
NOTE:
14.

> Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 00-10-3 > May > 00
> PCM - Engine Spark Knock While Accelerating > Page 4623

24. Select TRIGGER.
26. Select YES.

> Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 00-8-1 > Apr > 00 > PCM - Rough
PROM - Programmable Read Only Memory: Customer InterestPCM - Rough Idle On Cold Engine Start Up
Article No.00-8-1
DATE:04/17/2000
IDLE - ROUGH - AFTER COLD ENGINE START-UP (12 HOUR SOAK) - VEHICLES BUILT THROUGH 7/15/19
FORD: 1998-1999 CROWN VICTORIA
ISSUEA rough idle approximately 20 seconds after a cold engine start-up may occur on some vehicles. This condition
ACTIONPerform normal diagnostics in accordance with the Powertrain Control/Emissions Diagnosis (PC/ED) Service
Recalibration Information
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Eligible under the provisions of bumper to bumper warranty coverage and emmission warran

000801A reprogram powertrain 0.4 HR
control module (PCM)
42
OASIS CODES: 608000, 608400, 609000, 609400.

BASIC PART NO. CODE12A650
> Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 98-25-18 > Dec > 98 > Engine - De
PROM - Programmable Read Only Memory: Customer InterestEngine - Detonation/Knock In High Temperatu
Article No.98-25-18
12/21/98
DETONATION - DETONATION/SPARK KNOCKDURING ACCELERATION IN AMBIENTTEMPERATURES G
LINCOLN-MERCURY:1998 GRAND MARQUIS
CALIBRATION8-18F-R09/R12, 8-18H-R09/R12, 8-18I-R09/R12
WARNING
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE(S). PERFORMING THIS MODI
ISSUESome vehicles may exhibit a concern with light spark knock/detonation while accelerating in ambient temperatu
ACTIONReprogram Powertrain Control Module (PCM) with revised powertrain calibration. The revised calibration sh
SERVICE PROCEDURE
1. Perform normal diagnostics and repair as necessary.
2. If no engine or component concerns are identified, reprogram the PCM calibration using the latest level CD-ROM
98251BA Reprogram Powertrain 0.6 Hr.

Control Module (PCM)
> Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 98-25-18 > Dec >
98 > Engine - Detonation/Knock In High Temperatures > Page 4632

DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100

> Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 98-25-19 > Dec > 98 > PCM - MIL
Concerns
PROM - Programmable Read Only Memory: Customer InterestPCM - MIL ON/DTC P1506 Set/No Driveabilit
Article No.98-25-19
12/21/98
MALFUNCTION INDICATOR LAMP (MIL)ILLUMINATED - DIAGNOSTIC TROUBLE CODE(DTC) P1506

^
LAMP - MALFUNCTION INDICATOR LAMP (MIL)ILLUMINATED - DIAGNOSTIC TROUBLE CODE(DTC
CALIBRATION8-18M-R09/R13, 8-18N-R09/R13, 8-18Q-R09/R13, 8-18S-R09/R13
WARNING
ISSUEThe Malfunction Indicator Lamp (MIL) may illuminate with Diagnostic Trouble Code (DTC) P1506. This may
ACTIONReprogram the Powertrain Control Module (PCM) with latest calibration. Refer to the following Service Proc
SERVICE PROCEDURE
1. Retrieve, then clear DTCs from the PCM continuous memory.
2.
If DTC P1506 was present in continuous memory, perform normal diagnostics in accordance with the 1998 Powe
3.
If no problem was found after performing Step 2 and no other DTCs were present, reprogram the PCM using the
> Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 98-25-19 > Dec >
98 > PCM - MIL ON/DTC P1506 Set/No Driveability Concerns > Page 4637

982519A Reprogram Powertrain 0.6 Hr.

DEALER CODING
CONDITION
BASIC PART NO. CODE
RECALEM 42
OASIS CODES: 499000, 698298

> Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 98-19-7 > Sep > 98 > Engine - Hes
PROM - Programmable Read Only Memory: Customer InterestEngine - Hesistation When Accelerating
Article No.98-19-7
09/28/98
ISSUE
ACTION
NOTE
SERVICE PROCEDURE
2.

4.
NOTE
> Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 98-19-7 > Sep > 98
> Engine - Hesistation When Accelerating > Page 4642

DEALER CODING
CONDITION
BASIC PART NO. CODE
2C219 42
OASIS CODES: 301000, 607000, 607500, 611000, 611500, 614000, 614500

> Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programma
Dec > 04 > Engine Controls - General PCM Programming Procedures
PROM - Programmable Read Only Memory: All Technical Service BulletinsEngine Controls - General PCM Pr
TSB 04-24-14
12/13/04

SERVICE PROCEDURE
> 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 4648

NOTE
1.
NOTE
a.
a.
NOTE
PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4649

7.
11.
14.
Disclaimer
May > 00 > PCM - Engine Spark Knock While Accelerating
Article No.00-10-3
05/15/00

DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100
PROM - Programmable Read Only Memory: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 4654

Service Procedure
4. Select PCM.
NOTE:
14.

PROM - Programmable Read Only Memory: > 00-10-3 > May > 00 > PCM - Engine Spark Knock While Accelerating > Page 4655

24. Select TRIGGER.
26. Select YES.

Apr > 00 > PCM - Rough Idle On Cold Engine Start Up
PROM - Programmable Read Only Memory: All Technical Service BulletinsPCM - Rough Idle On Cold Engine
Article No.00-8-1
DATE:04/17/2000
IDLE - ROUGH - AFTER COLD ENGINE START-UP (12 HOUR SOAK) - VEHICLES BUILT THROUGH 7/15/19
FORD: 1998-1999 CROWN VICTORIA
ISSUEA rough idle approximately 20 seconds after a cold engine start-up may occur on some vehicles. This condition
ACTIONPerform normal diagnostics in accordance with the Powertrain Control/Emissions Diagnosis (PC/ED) Service
Recalibration Information
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Eligible under the provisions of bumper to bumper warranty coverage and emmission warran

000801A reprogram powertrain 0.4 HR
control module (PCM)
42
OASIS CODES: 608000, 608400, 609000, 609400.

BASIC PART NO. CODE12A650
Dec > 98 > Engine - Detonation/Knock In High Temperatures
PROM - Programmable Read Only Memory: All Technical Service BulletinsEngine - Detonation/Knock In High
Article No.98-25-18
12/21/98
DETONATION - DETONATION/SPARK KNOCKDURING ACCELERATION IN AMBIENTTEMPERATURES G
LINCOLN-MERCURY:1998 GRAND MARQUIS
CALIBRATION8-18F-R09/R12, 8-18H-R09/R12, 8-18I-R09/R12
WARNING
ISSUESome vehicles may exhibit a concern with light spark knock/detonation while accelerating in ambient temperatu
ACTIONReprogram Powertrain Control Module (PCM) with revised powertrain calibration. The revised calibration sh
SERVICE PROCEDURE
1. Perform normal diagnostics and repair as necessary.
2. If no engine or component concerns are identified, reprogram the PCM calibration using the latest level CD-ROM
98251BA Reprogram Powertrain 0.6 Hr.

PROM - Programmable Read Only Memory: > 98-25-18 > Dec > 98 > Engine - Detonation/Knock In High Temperatures > Page 4664

DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 42
OASIS CODES: 497000, 615000, 615500, 615600, 702000, 702100

Dec > 98 > PCM - MIL ON/DTC P1506 Set/No Driveability Concerns
PROM - Programmable Read Only Memory: All Technical Service BulletinsPCM - MIL ON/DTC P1506 Set/No
Article No.98-25-19
12/21/98
MALFUNCTION INDICATOR LAMP (MIL)ILLUMINATED - DIAGNOSTIC TROUBLE CODE(DTC) P1506

^
LAMP - MALFUNCTION INDICATOR LAMP (MIL)ILLUMINATED - DIAGNOSTIC TROUBLE CODE(DTC
CALIBRATION8-18M-R09/R13, 8-18N-R09/R13, 8-18Q-R09/R13, 8-18S-R09/R13
WARNING
ISSUEThe Malfunction Indicator Lamp (MIL) may illuminate with Diagnostic Trouble Code (DTC) P1506. This may
ACTIONReprogram the Powertrain Control Module (PCM) with latest calibration. Refer to the following Service Proc
SERVICE PROCEDURE
1. Retrieve, then clear DTCs from the PCM continuous memory.
2.
If DTC P1506 was present in continuous memory, perform normal diagnostics in accordance with the 1998 Powe
3.
If no problem was found after performing Step 2 and no other DTCs were present, reprogram the PCM using the
PROM - Programmable Read Only Memory: > 98-25-19 > Dec > 98 > PCM - MIL ON/DTC P1506 Set/No Driveability Concerns > Page 4669

982519A Reprogram Powertrain 0.6 Hr.

DEALER CODING
CONDITION
BASIC PART NO. CODE
RECALEM 42
OASIS CODES: 499000, 698298

Sep > 98 > Engine - Hesistation When Accelerating
PROM - Programmable Read Only Memory: All Technical Service BulletinsEngine - Hesistation When Acceler
Article No.98-19-7
09/28/98
ISSUE
ACTION
NOTE
SERVICE PROCEDURE
2.

4.
NOTE
PROM - Programmable Read Only Memory: > 98-19-7 > Sep > 98 > Engine - Hesistation When Accelerating > Page 4674

DEALER CODING
CONDITION
BASIC PART NO. CODE
2C219 42
OASIS CODES: 301000, 607000, 607500, 611000, 611500, 614000, 614500

> Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable R
> 04 > Engine Controls - General PCM Programming Procedures
PROM - Programmable Read Only Memory: All Technical Service BulletinsEngine Controls - General PCM Pr
TSB 04-24-14
12/13/04

SERVICE PROCEDURE
> 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 4680

NOTE
1.
NOTE
a.
a.
NOTE
> 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 4681

7.
11.
14.
Disclaimer
> Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specification

> Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specification

REMOVAL
CAUTION:
INSTALLATION
13 - 17 Nm (10 - 12 ft. lbs.)
13 - 17 Nm (10 - 12 ft. lbs.)
> Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Rep
REMOVAL

CAUTION:
> Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information >
Service and Repair > Page 4692

NOTE:
spring.
NOTE:

INSTALLATION

11 - 15 Nm (98 - 132 inch lbs.)
26 - 37 Nm (20 - 27 ft. lbs.)


7 - 10 Nm (62 - 88 inch lbs.).

19 - 26 Nm (14 - 19 ft. lbs.).
> Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 4704

REMOVAL
CAUTION:
INSTALLATION
13 - 17 Nm (10 - 12 ft. lbs.)
13 - 17 Nm (10 - 12 ft. lbs.)
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair
REMOVAL

CAUTION:
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair >
Page 4708

NOTE:
spring.
NOTE:
Page 4709

INSTALLATION
Page 4710

11 - 15 Nm (98 - 132 inch lbs.)
26 - 37 Nm (20 - 27 ft. lbs.)

Page 4711

7 - 10 Nm (62 - 88 inch lbs.).

19 - 26 Nm (14 - 19 ft. lbs.).
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 99
TCIL ON/Code P0782/Delayed/No 2-3 Upshift
Accumulator: Customer InterestA/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 DIAGNOSTICTROU

^
TRANSMISSION - 4R70W - DELAYED OR NO 2-3 UPSHIFT - VEHICLES BUILT BETWEEN 3/15/1997 AND
FORD:1997-1999 CROWN VICTORIA, MUSTANG, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250 LD
LINCOLN:1997-1998 MARK VIII1997-1999 TOWN CAR
MERCURY:1997-1999 GRAND MARQUIS, MOUNTAINEER
This TSB article is being republished in its entirety to revise the Service Procedure.
ISSUEA perceived 2-3 delayed upshift, primarily when the transmission is cold, may be evident on some vehicles. The
ACTIONVerify if delayed upshift is normal cold shift scheduling or a possible leak past the large diameter 2-3 accumu
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 sh
3.
If engine rpm decreases within 1-2 seconds after the gear command has changed on the NGS Tester, then vehicle
4.
If engine rpm does not drop when the PCM commands third gear, then replace the 2-3 accumulator piston using t

F7AZ-7H292-AB Accumulator Piston
SUPERSEDES: 99-1-3
WARRANTY STATUS: Eligible Under the Provisions Of Bumper To Bumper Warranty Coverage
991805A Replace Accumulator 1.8 Hrs.

Piston Per Service
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Accumulator: > 99-18-5 > Sep > 99 > A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift > Page 4723

Procedure (IncludesDiagnosis)
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

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 99
Remanufactured) Delayed or No 2-3 Upshift
Accumulator: Customer InterestA/T - 4R70W (Remanufactured) Delayed or No 2-3 Upshift
Article No.99-9-6
05/17/99
FORD:1994-1997 THUNDERBIRD1995-1998 CROWN VICTORIA1996-1998 MUSTANG
LINCOLN-MERCURY:1993-1998 MARK VIII1994-1997 COUGAR1995-1998 GRAND MARQUIS, TOWN CAR
LIGHT TRUCK:1994-1998 ECONOLINE, F-1501996-1998 EXPLORER1997-1998 EXPEDITION, F-25O LD, MOU
This concern is ONLY for vehicles with Ford Quality Remanufactured (FQR) 4R70W Transmission Exchange Units W
ISSUEA delayed or no 2-3 upshift, primarily when the transmission is cold, may be evident on some vehicles In some
ACTIONReplace the 2-3 accumulator piston using a revised piston. The revised piston will increase seal/bore interfere
F7AZ-7H292-AB Piston
990906A Replace Accumulator 1.0 Hr.

Piston
DEALER CODING
CONDITION
BASIC PART NO. CODE
7H292 42
OASIS CODES: 501000, 504000
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accu
4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift
Accumulator: All Technical Service BulletinsA/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 DIAGNOSTICTROU

^
TRANSMISSION - 4R70W - DELAYED OR NO 2-3 UPSHIFT - VEHICLES BUILT BETWEEN 3/15/1997 AND
FORD:1997-1999 CROWN VICTORIA, MUSTANG, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250 LD
LINCOLN:1997-1998 MARK VIII1997-1999 TOWN CAR
MERCURY:1997-1999 GRAND MARQUIS, MOUNTAINEER
This TSB article is being republished in its entirety to revise the Service Procedure.
ISSUEA perceived 2-3 delayed upshift, primarily when the transmission is cold, may be evident on some vehicles. The
ACTIONVerify if delayed upshift is normal cold shift scheduling or a possible leak past the large diameter 2-3 accumu
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 sh
3.
If engine rpm decreases within 1-2 seconds after the gear command has changed on the NGS Tester, then vehicle
4.
If engine rpm does not drop when the PCM commands third gear, then replace the 2-3 accumulator piston using t

F7AZ-7H292-AB Accumulator Piston
SUPERSEDES: 99-1-3
WARRANTY STATUS: Eligible Under the Provisions Of Bumper To Bumper Warranty Coverage
991805A Replace Accumulator 1.8 Hrs.

Piston Per Service
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Accumulator: > 99-18-5 > Sep > 99 > A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift > Page 4733

Procedure (IncludesDiagnosis)
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

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accu
4R70W (Remanufactured) Delayed or No 2-3 Upshift
Accumulator: All Technical Service BulletinsA/T - 4R70W (Remanufactured) Delayed or No 2-3 Upshift
Article No.99-9-6
05/17/99
FORD:1994-1997 THUNDERBIRD1995-1998 CROWN VICTORIA1996-1998 MUSTANG
LINCOLN-MERCURY:1993-1998 MARK VIII1994-1997 COUGAR1995-1998 GRAND MARQUIS, TOWN CAR
LIGHT TRUCK:1994-1998 ECONOLINE, F-1501996-1998 EXPLORER1997-1998 EXPEDITION, F-25O LD, MOU
This concern is ONLY for vehicles with Ford Quality Remanufactured (FQR) 4R70W Transmission Exchange Units W
ISSUEA delayed or no 2-3 upshift, primarily when the transmission is cold, may be evident on some vehicles In some
ACTIONReplace the 2-3 accumulator piston using a revised piston. The revised piston will increase seal/bore interfere
F7AZ-7H292-AB Piston
990906A Replace Accumulator 1.0 Hr.

Piston
DEALER CODING
CONDITION
BASIC PART NO. CODE
7H292 42
OASIS CODES: 501000, 504000
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Page 4738
Accumulator: Description and Operation
1-2 ACCUMULATOR
The 1-2 accumulator (in the case) is used to soften the 1-2 shift by absorbing some of the pressure directed to the inte
2-3 ACCUMULATOR
The 2-3 accumulator is used to soften the 2-3 shift by absorbing some of the direct clutch pressure. Forward clutch p
Accumulator: Service and Repair
To service the 1-2 or 2-3 accumulators or the overdrive or reverse servo assemblies use the following procedure.
REMOVAL
1. Remove the main control valve body. This illustration shows the position of the overdrive servo, the reverse band
accumulator piston and the 1-2 accumulator piston.
2. Remove the 2-3 accumulator spring retainer.


3. Remove 2-3 accumulator piston.
4. Use Servo Piston Remover/Replacer 307-251 (T92P-70023-A) to compress the overdrive servo piston return sprin
remove retainer ring.
NOTE:
If tool is not available, extreme care must be taken. Spring pressure will force overdrive servo piston assembly o

5. Remove piston assembly. Remove overdrive servo piston return spring.6. Use Servo Piston Remover/Replacer 307
accumulator piston retaining ring.
7. Remove reverse band servo cover, reverse band servo piston and rod and reverse band servo spring.
NOTE:
The length of the rod attached to the piston is graded for three different lengths. Therefore, they should not be in

8. Apply downward pressure on 1-2 accumulator cover using Servo Piston Remover/Replacer 307-251 (T92P-70023
remove 1-2 accumulator piston retaining ring.
9. Remove accumulator piston and 1-2 accumulator spring.
NOTE:
Carefully note the location of the 1-2 accumulator spring and assemble in the same positions. Some models may
INSTALLATION

1. Install reverse band servo spring, reverse band servo piston and rod. When piston and rod assembly replacement b
reverse band has been replaced, determine the correct length of the reverse servo piston and rod, proceed as follo
c. Install Servo Piston Selection Tool 307-073 (T80L-77030-A). Tighten the band apply bolt on Servo Piston Sel
5.6 Nm (50 inch lbs.)(T80L-77030-A) to .
d. Attach Dial Indicator with Bracketry 100-002 (TOOL-4201-C) or equivalent and position the indicator stem on
Zero the dial indicator.
e. Thread the bolt out of the selector tool until the piston stops against the, bottom of the tool.f.
2.845
Read - 6.0210ofmm
the amount (0.112
piston - 0.237
travel on theinch)
dialIfindicator.-
the travel is , the piston length is within specification.

-
If the travel is not within specification, selective pistons are available in the following lengths:ID74.56 mm
Select the proper rod to bring the servo piston travel within specification.
g. Lubricate the cover seal to facilitate assembly and to prevent damage to the seal.h. Remove the servo selection
NOTE: This is not an ordinary installation procedure and does not compensate for band wear.
2. Install Servo Piston Remover/Replacer 307-251 (T92P-70023-A) to transmission case.3. Tighten screw on Servo P
4. Install reverse servo retaining ring and remove tool.
CAUTION: Make sure reverse servo retaining ring is completely seated before removing tool or servo cover wi
5. Install overdrive servo piston return spring and overdrive servo piston assembly. Verify tip of piston assembly eng
band. Using Servo Piston Remover/Replacer 307-251 (T92P-70023-A), install piston assembly into the case and
6. Tighten tool until piston is below retaining ring groove and install retaining ring, remove tool.

7. Install the components for 2-3 accumulator in the following order:
NOTE: Retainer is secured by main control
- accumulator piston
- accumulator piston spring
- rear band servo spring retainer
8. Assemble the components for 1-2 accumulator in the following order:

- 1-2 accumulator spring
- cover and seal assembly
- accumulator piston retaining ring

9. Install the 1-2 accumulator assembly and spring to case. Install cover and seal assembly. Install retaining ring.
10. Install main control valve body.
11. Install fluid filter and grommet.

12 - 15 Nm (107 - 132 inch lbs.)12. Clean, inspect and install oil pan to case gasket and transmission pan. Tighten all
13. Install transmission shift linkage to manual control lever.14. Pour 4.7 liters (5 quarts) of MERCON V Automatic T
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Specifications
Band Apply Servo: Specifications

Piston Travel:
[a]Reverse Servo ...................................................................................................................................................... 2.8
[b]Selective Servo Pistons Rod Length :
1 Groove ...........................................................................................................................................................................
[a]
[b] Piston travel can be adjusted using one of the selective servo pistons available for service. Measured from the piston
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Specifications > Page 4750
Band Apply Servo: Service and Repair
To service the 1-2 or 2-3 accumulators or the overdrive or reverse servo assemblies use the following procedure.
REMOVAL
1. Remove the main control valve body. This illustration shows the position of the overdrive servo, the reverse band
accumulator piston and the 1-2 accumulator piston.
2. Remove the 2-3 accumulator spring retainer.


3. Remove 2-3 accumulator piston.
4. Use Servo Piston Remover/Replacer 307-251 (T92P-70023-A) to compress the overdrive servo piston return sprin
remove retainer ring.
NOTE:
If tool is not available, extreme care must be taken. Spring pressure will force overdrive servo piston assembly o

5. Remove piston assembly. Remove overdrive servo piston return spring.6. Use Servo Piston Remover/Replacer 307
accumulator piston retaining ring.
7. Remove reverse band servo cover, reverse band servo piston and rod and reverse band servo spring.
NOTE:
The length of the rod attached to the piston is graded for three different lengths. Therefore, they should not be in

8. Apply downward pressure on 1-2 accumulator cover using Servo Piston Remover/Replacer 307-251 (T92P-70023
remove 1-2 accumulator piston retaining ring.
9. Remove accumulator piston and 1-2 accumulator spring.
NOTE:
Carefully note the location of the 1-2 accumulator spring and assemble in the same positions. Some models may
INSTALLATION

1. Install reverse band servo spring, reverse band servo piston and rod. When piston and rod assembly replacement b
reverse band has been replaced, determine the correct length of the reverse servo piston and rod, proceed as follo
c. Install Servo Piston Selection Tool 307-073 (T80L-77030-A). Tighten the band apply bolt on Servo Piston Sel
5.6 Nm (50 inch lbs.)(T80L-77030-A) to .
d. Attach Dial Indicator with Bracketry 100-002 (TOOL-4201-C) or equivalent and position the indicator stem on
Zero the dial indicator.
e. Thread the bolt out of the selector tool until the piston stops against the, bottom of the tool.f.
2.845
Read - 6.0210ofmm
the amount (0.112
piston - 0.237
travel on theinch)
dialIfindicator.-
the travel is , the piston length is within specification.

-
If the travel is not within specification, selective pistons are available in the following lengths:ID74.56 mm
Select the proper rod to bring the servo piston travel within specification.
g. Lubricate the cover seal to facilitate assembly and to prevent damage to the seal.h. Remove the servo selection
NOTE: This is not an ordinary installation procedure and does not compensate for band wear.
2. Install Servo Piston Remover/Replacer 307-251 (T92P-70023-A) to transmission case.3. Tighten screw on Servo P
4. Install reverse servo retaining ring and remove tool.
CAUTION: Make sure reverse servo retaining ring is completely seated before removing tool or servo cover wi
5. Install overdrive servo piston return spring and overdrive servo piston assembly. Verify tip of piston assembly eng
band. Using Servo Piston Remover/Replacer 307-251 (T92P-70023-A), install piston assembly into the case and
6. Tighten tool until piston is below retaining ring groove and install retaining ring, remove tool.

7. Install the components for 2-3 accumulator in the following order:
NOTE: Retainer is secured by main control
- accumulator piston spring
- rear band servo spring retainer
8. Assemble the components for 1-2 accumulator in the following order:

- cover and seal assembly
- accumulator piston retaining ring

9. Install the 1-2 accumulator assembly and spring to case. Install cover and seal assembly. Install retaining ring.
10. Install main control valve body.

12 - 15 Nm (107 - 132 inch lbs.)12. Clean, inspect and install oil pan to case gasket and transmission pan. Tighten all
13. Install transmission shift linkage to manual control lever.14. Pour 4.7 liters (5 quarts) of MERCON V Automatic T
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Specifications
Case: Specifications
Extension Housing Bolts .....................................................................................................................................................

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Specifications > Page 4761
Case: Testing and Inspection
Inspect case for cracks and stripped threads. Inspect gasket surfaces and mating surfaces for burrs. Check vent for obstr
Inspect case bushing for scores. Check all parking linkage parts for wear or damage.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications
Clutch: Specifications
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Page 4765
Clutch: Application and ID
Band/Clutch Application Chart #601
Band/Clutch Application Chart #601

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Page 4766
Clutch: Description and Operation
The forward clutch cylinder and shaft transfers speed and torque from the converter turbine to the gear train. This sha
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Testing and Inspection > Direct Clutch
Clutch: Testing and InspectionDirect Clutch

FORWARD, DIRECT, INTERMEDIATE, OVERDRIVE AND REVERSE CLUTCHES
1. Inspect clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or b
crocus cloth. Replace clutch cylinder if badly scored or damaged.
2. Check fluid passage in clutch cylinder for obstructions. Clean out all fluid passages. Inspect bearing surfaces for s
scores are found, replace output shaft and inspect components.
2. Check splines on output shaft for wear; replace output shaft if splines are excessively worn. Inspect all bushings.3
deeply scored or burred.
5. Check clutch plates for flatness and fit on clutch hub serrations. Discard any plate that does not slide freely on serr
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Testing and Inspection > Direct Clutch > Page 4769
Clutch: Testing and InspectionForward Clutch

Clutch: Testing and InspectionIntermediate Clutch

Clutch: Testing and InspectionOne-Way Clutch, A/T
1. Inspect outer and inner races for scores or damaged surface areas where rollers contact races.2. Inspect rollers and
Clutch: Testing and Inspection
Direct Clutch
Forward Clutch
Intermediate Clutch
One-Way Clutch, A/T
1. Inspect outer and inner races for scores or damaged surface areas where rollers contact races.2. Inspect rollers and
Overdrive Clutch
2. Check
scoresfluid passage
are found, in clutch
replace cylinder
output shaft for
andobstructions. Clean out all fluid passages. Inspect bearing surfaces for s
inspect components.
Reverse Clutch

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Specifications
Automatic Transmission Dipstick - Dipstick Tube: Specifications

Fluid Filler Tube Bolt ..........................................................................................................................................................
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications
Fluid - A/T: Capacity Specifications
A/T Fluid Capacity ..............................................................................................................................................................
A/T Fluid Refill ...................................................................................................................................................................
NOTE: With engine at operating temperature, shift through all gears. Check fluid in PARK add fluid as needed.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 4784
Fluid - A/T: Fluid Type Specifications

Fluid Type ............................................................................................................................................................................
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4785
Fluid - A/T: Service Precautions

NOTE:
Do NOT use ANY non-approved automatic transmission fluid for an application specifying MERCON V OR MER
Care must be taken to use the correct fluid for the specific application. Be sure to check the container label to insure
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4786
Fluid - A/T: Service and Repair
Normal maintenance and lubrication requirements necessitate periodic automatic transmission fluid changes. If a ma
CAUTION: Use of a fluid other than specified could result in transmission malfunction and/or failure.
Refer to the vehicle certification label affixed to the LH front door lock face panel or door pillar for the transmission
When filling a dry transmission or torque converter, refer to Specifications for capacity. Check the fluid level.
Procedures for partial drain and refill, due to in-vehicle service operation, are as follows:1. Raise and suitably suppor
slowly.
28 - 30 Nm (21 - 22 ft. lbs.)
5. Drain the torque converter by removing the torque converter drain plug.6. After the torque converter has been drai
9. Lower vehicle.
6.1 liters (6.5 quarts)
10. When filling a dry transmission and converter, start with a minimum of .11. Fill transmission to proper level using
V specification.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications
Fluid Line/Hose: Specifications
Cooler Fittings to Case ........................................................................................................................................................

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > Page 4790
Fluid Line/Hose: Testing and Inspection

BACK FLUSH /CLEANING
1. Perform back flushing with a Rotunda Torque Converter Cleaner 307-FO11 or equivalent. Test your equipment to
flow is present before proceeding. Replace the system filter if flow is weak or contaminated.
2. To aid in attaching the cleaner to the transmission steel cooler tubes, connect two additional rubber hoses to the tra
(OTA)Disconnect
transmission the as
cooler tubes fluid cooler tubes
described from the Oil-To-Air cooler.
below.-
- Install a rubber hose in place of the oil-to-air cooler.
- Connect the cleaner tank pressure line to the steel transmission cooler return tube (longer tube).
-
Connect a tank return hose to the steel transmission cooler pressure tube (shorter tube). Place the outlet end of
3. Turn on solvent pump and allow the solvent to circulate a minimum of five minutes (cycling switch on and off wil
the cooler tubes).
(OTA)4. Switch off the solvent pump and disconnect the solvent pressure hose from the transmission cooler return tu
Fluid Line/Hose: Service and Repair
20 - 26 Nm (15 - 19 ft. lbs.)

24 - 31 Nm (18 - 22 ft. lbs.)
When one or more of the cooler inlet tube and cooler tube must be replaced, each replacement tube must be fabricate
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications
Fluid Pan: Specifications

Pan Retaining Bolts .............................................................................................................................................................
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications
Fluid Pump: Specifications
Stator Support-to-Pump Body .............................................................................................................................................

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Input Shaft, A/T > Component Information > Description and Operation
Input Shaft: Description and Operation
The forward clutch cylinder and shaft transfers speed and torque from the converter turbine to the gear train. This for
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments
1.4 kg (3 lbs.)
adjustment.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments > Page 4806

REMOVAL
INSTALLATION
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Service and Repair > D

DISASSEMBLY
forward.
range indicator.
ASSEMBLY
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Service and Repair > D

REMOVAL
INSTALLATION
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications
Output Shaft: Specifications

Output Shaft Speed Sensor ..................................................................................................................................................
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications > Page 4815
Output Shaft: Description and Operation

The output shaft provides torque to the propeller shaft and rear axle assembly. It is driven by the ring gear of the plan
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications > Page 4816
Output Shaft: Testing and Inspection
1. Inspect output shaft bearing surfaces for scores. If excessive clearance or scores are found, replace output shaft an
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control Switch <--> [Overdrive Switch, A/T] > Component Information > Description and Operation

(PCM)
(TCIL)
OPERATION
TheThe system
range engages
transmission mode
control switch each
in the time
shift theknob.-
-
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Description and Operation
Planetary Gears: Description and Operation
Theprimary sungear
planetary gearset in the transmission is a Ravigneaux-type set consisting of the following components:-
- reverse clutch gear and shell
- a pinion carrier
- long and short pinions
- ring gear
Members are driven or held to produce four forward gear ratios plus one reverse ratio.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Description and Operation > Page 4823
Planetary Gears: Testing and Inspection

1. Check pins and shafts in planet assemblies for loose fit and/or complete disengagement. Use new planet assembly
NOTE: Individual parts of the planet assemblies are not serviceable.
2. Inspect pinion gears for damaged or excessively worn teeth.3. Check for free rotation of pinion gears.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Control Switch <--> [Overdrive Switch, A/T] > Component Information >

(PCM)
(TCIL)
OPERATION
TheThe system
range engages
transmission mode
control switch each
in the time
shift theknob.-
-
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Custom
> 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative
Article No.02-13-6
07/08/02
ISSUE
ACTION
Parts Block

BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service
Bulletins > Customer Interest for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 4840

3.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Te
Article No.02-13-6
07/08/02
ISSUE
ACTION
Parts Block

BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 4846

3.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range (TR) Sensor <--> [Transmission Position Switch/Sensor, A/
Locations
Transmission View


7 - 10 Nm (62 - 88 inch lbs.).
19 - 26 Nm (14 - 19 ft. lbs.)
REMOVAL
INSTALLATION
(TR)
7 - 10 Nm (62-88 inch lbs.)
19 - 26 Nm (14 - 19 ft. lbs.)
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 486
Transmission View

REMOVAL
(VSS)
INSTALLATION
7 - 10 Nm (62 - 88 inch lbs.)

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Specifications

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 4867

REMOVAL
CAUTION:
INSTALLATION
13 - 17 Nm (10 - 12 ft. lbs.)
13 - 17 Nm (10 - 12 ft. lbs.)
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > Customer Inter
-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative
Article No.02-13-6
07/08/02
ISSUE
ACTION
Parts Block

BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins >
Customer Interest for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 4876

3.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins > All Technical S
Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative
Article No.02-13-6
07/08/02
ISSUE
ACTION
Parts Block

BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 4882

3.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair
REMOVAL

CAUTION:
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > Page 4886

NOTE:
spring.
NOTE:

INSTALLATION

11 - 15 Nm (98 - 132 inch lbs.)
26 - 37 Nm (20 - 27 ft. lbs.)


7 - 10 Nm (62 - 88 inch lbs.).

19 - 26 Nm (14 - 19 ft. lbs.).
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Locations
Shifter A/T: Locations

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Locations > Page 4893
Shifter A/T: Testing and Inspection

NOTE: Ignition switch must be in RUN and brake pedal applied or transmission range selector lever cannot be mov
1. Make sure there is a click at each range when shifted from PARK to LOW.2. Check that positions of transmission
linkage as outlined.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Locations > Page 4894
Shifter A/T: Service and Repair
REMOVAL
1. Remove tilt wheel handle and shank by unscrewing it from the steering column release lever.2. Turn ignition switc
ignition switch lock cylinder.
3. Remove lower instrument panel cover retaining screws and remove cover.4. Remove four retaining screws from lo
INSTALLATION
1. If removed, install shift lever clip into opening in gearshift lever as shown.2. Insert gearshift lever through hole in
visible on bottom of shifter housing.
5. Position shift lever seal assembly on the steering column lock cylinder housing. Insert lower attachment into the sl
lock cylinder housing.
6. Position upper attachment on mounting pin and press into place. Install a Tinnerman nut to secure cover to pedesta
cylinder housing.
7. Install upper steering column shroud and lower steering column shroud with four screws.8. Install lower instrumen
10. Install tilt wheel handle and shank onto steering column release lever.11. Check for proper start in PARK and NEU
column is locked in the LOCK position.
> 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
4. Remove 14 pan retaining bolts, transmission pan and pan to case gasket.5. Disconnect transmission shift linkage f

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair > Page 4899

CAUTION:
NOTE:
(TR)8. Remove two bolts retaining digital Transmission Range sensor to case. Remove transmission range sensor fr
9. Remove one bolt retaining manual control valve detent lever spring to the main control valve body.
11. Using a 13/16-inch open-end wrench on the inner nut and a 12 mm wrench on the manual control lever shaft flats,

Slide manual control lever partially out of the case to complete removal of the inner nut from manual control leve
12. Using a screwdriver on the manual control lever seal lower edge, carefully pry manual control lever seal out of cas
NOTE: Do not damage bore with the prying tool.
INSTALLATION
26 - 37 Nm (20 - 27 ft. lbs.)1. Install new manual control lever seal using Shift Lever Seal Replacer 307-060 (T74P-
Install manual lever shaft retaining pin.
9 - 11 Nm (80 - 97 inch lbs.)4. Install manual control valve detent lever spring and one bolt. Tighten to .

6. Install digital TR sensor on manual control lever and two shims, then loosely install bolts.7. Position manual contr
tabs on tool.
7 - 10 Nm (62 - 8 inch lbs.)9. Tighten digital TR sensor bolts to .

12 - 15 Nm (107 - 132 inch lbs.)10. Clean, inspect and install pan to case gasket and transmission pan. Tighten all bo
11. Install transmission linkage to manual control lever.12. Pour 4.7 liters (5 quarts) of MERCON V Automatic Trans
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications
Shift Cable: Specifications
Transmission Cable to Transmission Range Selector .........................................................................................................

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 4906
Shift Cable: Service and Repair

REMOVAL
1. From under instrument panel, remove cable plastic terminal from the gearshift lever pivot ball by prying with a sc
terminal and transmission range selector lever.
2. Remove shift cable and bracket from the steering column tube.3. Raise vehicle.
4. Remove shift cable and bracket from transmission shift cable bracket by unlocking lock tabs of shift actuator cable
bracket.
5. Remove nut retaining cable to transmission manual control lever stud and remove cable from stud.6. Remove shift
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 4907

INSTALLATION
1. From engine compartment, feed plastic terminal end of cable through cowl.2. From passenger compartment, pull t
locking tab is fully seated.
4. Install shift cable and bracket to steering column casting.5. Attach cable plastic terminal to shift lever pivot ball. P
weight on the end.
NOTE: Apply small amount of grease to column selector lever pivot ball, or cable terminal.
6. From engine compartment, route the shift cable to bracket on crossmember and through clip on fuel rail bracket. In
25.4 mm (1.0 inch)bracket. Position the cable so that the white band on cable is from the grommet.
7. Raise vehicle. Install cable in shift cable bracket. Clip the transmission shift cable into transmission bracket. Ensur
1.4 kg (3 lb.)10. Lower vehicle.11. Remove weight.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service T
Sun Gear: Technical Service BulletinsA/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 - SERVIC
FORD:1994-1997 THUNDERBIRD,1994-2003 CROWN VICTORIA, MUSTANG, E SERIES1996-2001 EXPLORER
LINCOLN:1994-1998 MARK VIII 1994-2003 TOWN CAR
MERCURY:1994-1997 COUGAR 1994-2003 GRAND MARQUIS1997-2001 MOUNTAINEER
ISSUEShould repairs become necessary on a 4R70W transmission involving replacement of the forward or reverse clu
ACTIONA 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)
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/
Race Kit Service Tip > Page 4912

^ 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
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/
Race Kit Service Tip > Page 4913

Parts Block
Disclaimer
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Thrust Washer/Bearing, A/T > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/
Thrust Washer/Bearing: Technical Service BulletinsA/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 - SERVIC
FORD:1994-1997 THUNDERBIRD,1994-2003 CROWN VICTORIA, MUSTANG, E SERIES1996-2001 EXPLORER
LINCOLN:1994-1998 MARK VIII 1994-2003 TOWN CAR
MERCURY:1994-1997 COUGAR 1994-2003 GRAND MARQUIS1997-2001 MOUNTAINEER
ISSUEShould repairs become necessary on a 4R70W transmission involving replacement of the forward or reverse clu
ACTIONA 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)
> 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 4918

^ 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
> 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 4919

Parts Block
Disclaimer
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications
Torque Converter: Specifications

End Play:
New or Rebuilt .............................................................................................................................................................. 0
Converter-to-Flywheel Nuts .............................................................................................................................................

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 4923
Torque Converter: Description and Operation
Theimpeller assemblytransmits and multiplies torque. The torque converter is a four-element device:-
torque converter
- turbine assembly
- reactor assembly
- clutch and damper assembly
TheRotation
standardof the converter
torque converterhousing and impeller
components operate set the fluid in motion.
as follows:-
- The turbine reacts to the fluid motion from the impeller, transferring rotation to the gear train through the input sh
- The reactor redirects fluid going back into the impeller, allowing for torque multiplication.
- The clutch
Power and damper
is transmitted assembly
from dampens
the torque powertrain
converter torsional gear
to the planetary vibration andother
sets and provides a direct mechanical
components through theconne
input
Torque Converter: Testing and Inspection
When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or band materi
(OTA)Whenever a transmission has been disassembled to replace worn or damaged parts or because the valve body
Flush the torque converter of the remaining solvent using this procedure:1. Thoroughly drain the remaining solvent t
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications
Transmission Cooler: Specifications

Cooler Mounting Bolts ........................................................................................................................................................
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 4932
Transmission Cooler: Description and Operation
FLUID COOLER - OIL-TO-AIR (OTA)
The transmission fluid cooler is an oil-to-air fluid cooler with a thermostatic bypass valve. The fluid cooler is mounte
When the transmission or fluid is cold and the thermostatic bypass valve is closed, transmission fluid does not cir
-
As transmission fluid temperature increase, the thermostatic bypass valve opens and allows transmission fluid to
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Over
Transmission Cooler: Initial Inspection and Diagnostic Overview

(OTA)When fluid leakage is found in the Oil-To-Air fluid cooler, replace the OTA fluid cooler.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Over
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Flushing
Transmission Cooler: Service and RepairFlushing
When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or band materi
(OTA)Whenever a transmission has been disassembled to replace worn or damaged parts or because the valve body
Flush the torque converter of the remaining solvent using this procedure:1. Thoroughly drain the remaining solvent t
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Flushing > Page 4938
Transmission Cooler: Service and RepairRemoval and Installation

REMOVAL
1. Remove radiator cover.2. Remove air filter assembly. 3. Remove the battery.4. Remove power steering lines from
INSTALLATION
16 - 20 Nm (12 - 14 ft. lbs.)
17 - 22 Nm (13 - 16 ft. lbs.)
1. Position fluid cooler. Install two fluid cooler mounting bolts. Tighten to .2. Install two upper radiator mount brack
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Indicator - A/T > Component Information > Service and Repair > Disassembly and Assembly

DISASSEMBLY
forward.
range indicator.
ASSEMBLY
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Indicator - A/T > Component Information > Service and Repair > Disassembly and Assembly > Pa

REMOVAL
INSTALLATION
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/
Article No.99-11-1
06/14/99
^
^
CONTENTS
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive
Noise/Vibration/Harshness Procedure > Page 4951

GENERAL PROCEDURES
Diagnostic Theory

Diagnostic Process

Glossary of Terms

Dynamic Balance







a.
c.
d.

-
Vibrate Software(R)

ChassisEAR
EngineEAR


Tracing Powder
d.

Diagnostic Process




2. Pre-Drive Check
important
^
^
^
^
5. Road Test
Note:
^

speed-related.
^
^
^

^

Steering Input Test
^
Brake Test
^
^
^
^

^ WARNING:
^ CAUTION:

^
WARNING:
CAUTION:
Note:
^
^ Start the engine.
^ CAUTION:

1. Static operation
^
2. While cranking
3. At idle
^
1.
1. Speed related
-
Idle vibration
-

-

-
-
Airvaries
Noise Leak with
wind/vehicle
2. Acceleration
-
4. Braking.
^
^
^
5. Clutching

6. Shifting
^
8. Cruising speeds
1.




































Pinpoint Tests































1. Open the hood.
2. Note:
Note:
4.
3. CAUTION:

3.
6.
7.

^



WARNING:
4. CAUTION:

WARNING:
WARNING:
Note:
1. WARNING:

CAUTION:
6.
^

Wheel Bearing Check
1. WARNING:

2. Note :

^
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range (TR) Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information >
Transmission View


7 - 10 Nm (62 - 88 inch lbs.).
19 - 26 Nm (14 - 19 ft. lbs.)
REMOVAL
INSTALLATION
(TR)
7 - 10 Nm (62-88 inch lbs.)
19 - 26 Nm (14 - 19 ft. lbs.)
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 5056
Transmission View

REMOVAL
(VSS)
INSTALLATION
7 - 10 Nm (62 - 88 inch lbs.)

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications
Valve Body: Specifications

Cover Plate-to-Valve Body ..................................................................................................................................................
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 5062
Valve Body: Description and Operation
Thetwo shift
main solenoids.
control valve body houses three electronic solenoids:-
- (TCC solenoid)Torque Converter Clutch solenoid .
Valve Body: Testing and Inspection

1. Clean all parts, except non-metallic coasting booster valve shuttle balls, thoroughly in clean solvent and blow dry
air.
2. Inspect all valve and plunger bores for scores. Check all fluid passages for obstructions. Inspect all mating surface
NOTE: If necessary, use crocus cloth to polish valves and plungers. Avoid rounding sharp edges of valves and p
3. Inspect all springs for distortion. Check all valves and plungers for free movement in their respective bores. Valve
fall from their own weight in their respective bores.
4. Roll manual control valve on a flat surface to check for bent condition.
Valve Body: Service and Repair

REMOVAL
1. Disconnect the battery ground cable.2. Raise vehicle on a hoist.3. Drain transmission fluid.4. Remove 14 pan retai
NOTE:
CAUTION:
It installing a new filter, and grommet remains in the main control bore, carefully use, a small screwdriver to rem
7. Disconnect the molded lead frame from the sensors.
CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry

the sensors.
(EPC)8. Remove one bolt retaining manual control valve detent lever spring to the main control valve body.9. Remo
10. Remove remaining 23 valve body-to-case retaining bolts, the main control valve body and the valve-to-body gask

INSTALLATION
(EPC)1. Position main control valve body using the two alignment bolts as a guide.2. Install the Electronic Pressure
3. Loosely install II long and 12 short bolts.4. Install manual control valve detent lever spring and one bolt.
9 - 11 Nm (80 - 97 inch lbs.)5. Tighten the 25 main control-to-case valve body bolts to .

6. Install the molded lead frame to the sensors.7. Connect the molded lead frame to the sensors.
- Connect the bulkhead inter connector.
- (EPC)Connect the Electronic Pressure Control solenoid.
- (TCC)Connect the Torque Converter Clutch .
- Connect the shift solenoid SSA /SS1 and SSB/SS2.
8. Install filter and grommet.


9. Install pan magnet to transmission pan.
12 - 15 Nm (107 - 132 inch lbs.)10. Clean, inspect and install pan-to-case gasket and transmission pan. Tighten all bo

11. Lower vehicle.12. Pour 4.7 liters (5 quarts) of MERCON V Automatic Transmission Fluid XT-5-QM or equivalen
> Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Differential Case Removal
Differential Case: Service and RepairDifferential Case Removal
1. Raise vehicle and place jackstands under rear frame crossmember. Lower the hoist so that the rear axle housing is
Rear Axle Removal
6. Working with axle housing Cover removed, remove differential pinion shaft lock pin and remove the differential p
pinion gears.
7. Push axle shaft inward until U-washers at button end of the axle shaft are clear of the differential side gear recess.
8. Remove U-washers and pull axle shafts out of the rear axle housing.
> Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Differential Case Removal > Page 5074

CAUTION:
Do not damage inner wheel bearing oil seal or rear brake anti-lock sensor indicator when removing axle shafts fro
9. Mark the driveshaft centering socket yoke and rear axle universal joint flange to make sure alignment is proper at
from rear axle universal joint flange. Remove driveshaft assembly from vehicle. Insert Extension Housing Seal R
10. Mark one differential bearing cap to help position the caps properly during assembly.
CAUTION: Bearing caps MUST be installed in their original positions during assembly. Note direction of arrow
11. Loosen differential bearing cap bolts and bearing caps.

12. Pry differential case, differential bearing cups and differential bearing shims out until they are loose in the bearing
remove differential case from rear axle housing.

13. Inspect the differential bearings and differential bearing cups for damage. If damaged, remove the differential bea
205-DO72 (D97L-4221-A) or equivalent.
14. Install differential bearings using Differential Side Bearing Replacer 205-010 (T57L-4221-A2).
Differential Case: Service and RepairDifferential Case Disassembly and Assembly

DISASSEMBLY
1. Remove and discard the 10 rear axle differential ring gear bolts securing the ring gear to the differential case.
NOTE:
It is not necessary to remove the differential cone and roller assemblies from the case journals unless they are da
2. Remove the ring gear by tapping the gear with a soft-faced hammer or press the gear from the differential case.3. R
WARNING: USE CARE WHEN REMOVING THE DIFFERENTIAL CLUTCH SPRING BECAUSE OF
5. Rotate the differential pinion gears until the differential pinion gears and differential pinion thrust washers can be
"RH" and "LH."
7. Clean and inspect all parts for wear or damage. Replace as necessary.
NOTE: Do not use cleaning solvents on friction plate surfaces. Wipe clean only.
8. Adjust clutch pack preload.
ASSEMBLY
1. Lubricate all parts with specified rear axle lubricant. Soak all clutch plates in Additive Friction Modifier C8AZ-19
Ford specification EST-M2C118-A for fifteen minutes before assembly.
2. Mount the differential case in a soft-jaw vise and place the differential clutch packs and differential side gears in th
differential case.
3. Engage the differential pinion gears and differential pinion thrust washers with the differential side gears.4. Rotate
differential case.
5. With a soft-faced hammer, install the S-shaped differential clutch spring in the differential case. If necessary, com
differential clutch spring with a brass drift.
NOTE: Inspect the differential clutch spring for damage.


6. Clean the tapped holes in the differential ring gear and pinion with a suitable solvent. If the new bolts to be used sh
12.7 mm (1/2 inch)
95 - 115 Nm (70 - 84 ft. lbs.).approximately of the threaded area, use as is. If not coated, apply a small amount o
CAUTION: Always install new, differential pinion shaft lock pin.
NOTE:
Do not tighten the differential pinion shaft lock pin at this point. The differential pinion shaft and differential pin
Differential Case: Service and RepairDifferential Case Installation-Condition 1

Follow this procedure when only replacement of driveshaft is required and the differential bearings and differential cas
1. Remove the differential caps and bolts. Identify the RH cap, RH differential bearing cup and differential bearing s
as RH and LH sets.
2. Remove the differential case subassembly using the pry bar method. Reasonable effort will be required to remove
specification range. If subassembly can be removed by hand, use Differential Case Installation - Condition 2 for a
3. Replace the differential ring gear and pinion members using the original assembly and select the drive pinion bear
bearing shims may be reused with the exception of drive pinion bearing adjustment shim which will require regau
Differential Case: Service and RepairDifferential Case Installation-Condition 2
Follow this procedure when original differential bearing shims are not available or when rear axle housing, differenti
1. With pinion depth set and pinion installed, place the differential case/gear subassembly with differential bearings a
rear axle housing.
6.75 mm (0.265 inch)2. Install a differential bearing shim on the LH side.
3. Install LH bearing cap finger-tight.


4. Install differential bearing shims progressively on the RH side until the largest differential bearing shim selected c
drag feel.
95 - 115 Nm (70 - 85 ft. lbs.).5. Install RH side bearing cap and differential bearing cap bolts. Tighten to
6. Rotate the assembly to make sure differential assembly rotates freely.

7. Check gear and pinion backlash. If backlash is within specification, go to Step 14. If backlash is not within specifi
backlash is measured, proceed with Step 8.

0. 020 inch 0.020 inch
8. If a zero backlash occurs, add to the RH side and subtract from the LH side to allow backlash indication.9. Check
10. If backlash is not to specification, correct backlash by increasing thickness of one differential bearing shim and de
differential bearing shim by the same amount. Refer to the illustrations for approximate shim change.
Adjusting Backlash


95 - 115 Nm (70 - 85 ft. lbs.).11. Install differential bearing shim and bearing caps. Tighten cap bolts to
12. Rotate assembly several times.

13. Recheck backlash. If backlash is within specification, proceed to Step 14. If not, repeat Step 10.14. Increase both L
fully seated and the assembly turns freely.
15. Use a white marking compound to obtain a tooth mesh contact pattern in the assembly. Pattern legibility can be im
driveshaft and rotating both tires in the drive and coast direction.
> Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Adjustments
Differential Clutch: Adjustments
1. If installed, remove differential clutch packs.
WARNING: USE CARE WHEN REMOVING THE DIFFERENTIAL CLUTCH SPRING BECAUSE OF
2. Install Traction-Lok Clutch Gauge 205-135 (T80P-4946-A) on each of the side gear differential clutch packs with
6.7 Nm (60 inch lbs.)clutch shim. Tighten to .
> Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Adjustments > Page 5088

NOTE:
Soak all friction clutch plates in Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specif
3. Using a feeler gauge tool, select the thickest feeler blade that will enter between the Traction-Lok Clutch Gauge T
and the differential clutch pack. This reading will be the thickness of the new rear axle differential clutch shim.
4. Repeat Steps 1 through 4 for the opposite differential clutch pack.
NOTE: Do not mix the clutches or shims.
5. Install differential clutch packs.

> Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications
Differential Cover: Specifications

Axle Housing Cover Bolts ...................................................................................................................................................
> Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Page 5092
Differential Cover: Service and Repair

REMOVAL
1. Raise vehicle to desired working height.2. Clean all dirt from area of axle housing cover with a wire brush or cloth
INSTALLATION
1. Install axle housing cover using Silicone Rubber D6AZ-19562-AA or -BA or equivalent meeting Ford specificatio
38 - 52 Nm (28 - 38 ft. lbs.).ESE-M4G195-A. Tighten axle housing cover bolts to
CAUTION:
Make sure machined surfaces of both axle housing cover and rear axle housing are free of old gasket material bef
NOTE: Axle housing cover must be installed within 15 minutes of application of sealer or new sealer must be a
62. Fill axle with Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C
- 14 mm (1/4 - 9/16 inch) 118 ml (4 oz)
20 - 40 Nm (15 - 29 ft. lbs.). below bottom fill hole. Add of Additive Friction Modifier C8AZ-1913546-A or eq
CAUTION: Overfilling axle can cause rear axle housing vent and seal leakage.
3. Make sure rear axle housing vent is not plugged with debris.
> Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Testing and Inspection > Differential Axle Housing
Differential Axle Housing: Testing and InspectionDifferential Axle Housing
Casting Porosity (Holes In Casting)
Rear axle lubricant may leak through small pockets in the material of the axle housing casting. These pockets (castin
manufacturing standard M3D35-A(E).
Weld Leaks
Most minor weld leaks can be corrected with epoxy sealer meeting Ford manufacturing standard M3D35-A(E). This
> Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Testing and Inspection > Differential Axle Housing > Page 5097
Differential Axle Housing: Testing and InspectionDifferential/Axle Housing Vent

NOTE:
If rear axle housing vent cannot be cleared, it must be replaced using Stud and Bearing Mount EOAZ-19554-BA o
A plugged rear axle housing vent will cause excessive seal lip wear due to internal pressure buildup. When a leak oc
Make sure axle lubricant is level with bottom of fill hole.
> Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Differential/Axle Housing Vent
Differential Axle Housing: Service and RepairDifferential/Axle Housing Vent

REMOVAL
1. Raise vehicle on hoist.
2. Remove rear axle housing vent from rear axle housing.
INSTALLATION
1. Install rear axle housing vent into rear axle housing.2. Lower vehicle.
> Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Differential/Axle Housing Vent > Page 5100
Differential Axle Housing: Service and RepairDifferential Axle Housing
REMOVAL
1. Raise the vehicle on a hoist, and position safety stands under the rear frame crossmember.
WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF
2. Remove the wheel and tire assemblies.
3. Remove the rear disc brake caliper.
NOTE: Position the rear disc brake caliper forward of the axle, and support it with a length of wire.
4. Remove the rear disc brake rotor

5. Disconnect the parking brake rear cable and conduits from the parking brake lever.6. Disconnect the parking brake
cable and lift the inner cable through the slot. Position the parking brake rear cable and conduits out of the way.
> Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Differential/Axle Housing Vent > Page
5101

NOTE: Relieve the tension of the parking brake rear cable and conduits.
7. Remove the rear brake anti-lock sensors. Release the clips on the axle housing, and position the sensors aside.
8. Disconnect the rear stabilizer bar from the rear stabilizer bar link and bushing.
9. Remove the rear stabilizer bar bracket bolts, the rear stabilizer bar bracket and the rear stabilizer bar.
5102

10. Disconnect the air suspension height sensor from the watts linkage arm.11. Mark and remove the driveshaft.
12. Remove the watts linkage retaining nut.
13. Separate the watts linkage from the axle housing.

CAUTION: Take care not to damage the threads on the bellcrank stud.
14. Support the rear axle assembly with a Rotunda High-Lift Transmission Jack 164-R3508 or equivalent.
5103

15. Remove the shock absorber lower nuts, and separate the rear shock absorber from the mountings on the axle housi
16. Remove the rear suspension lower arm nuts and bolts.
17. Remove the rear suspension upper arm nuts and bolts.18. Unseat the rear springs from the axle housing.
19. Lower the axle, and remove it from the vehicle.
INSTALLATION
5104

1. Transfer all the components from the old rear axle housing to the new rear axle housing, and make the necessary a
preload.
2. Install new rear wheel bearings into the new rear axle housing using Axle Tube Bearing Replacer 205-124 (T78P-
3. Install a new inner wheel bearing oil seal using Axle Tube Seal Replacer 205-123 (T78P-1177-A). Apply Premium
X or equivalent meeting Ford specification ESA-M1C75-B between the lips of the inner wheel bearing oil seal.
4. Position the rear axle assembly under the vehicle and raise the axle with Rotunda High-Lift Transmission Jack 164
87 - 1196. Position the rear suspension upper arms into the brackets, and install the nuts and the bolts. Tighten the re
Nm (64 - 87 ft. lbs.).
5105

127 -7. Position the rear suspension lower arms into the brackets, and install the nuts and the bolts. Tighten the rear s
173 Nm (94 - 128 ft. lbs.).
76 - 103 Nm (57 - 75 ft. lbs.).8. Install the rear shock absorber in the shock absorber mounting bracket. Tighten the s
212 - 288 Nm (157 - 212 ft. lbs.).9. Install the wafts linkage onto the bellcrank stud. Tighten the watts linkage retain
5106

10. Connect the air suspension height sensor to the watts linkage arm.
21 - 29 Nm (16 - 21 ft. lbs.).

11. Install the rear stabilizer bar and the rear stabilizer bar brackets. Tighten the rear stabilizer bar bracket bolts to 12.
17 - 23 Nm (13 - 16 ft. lbs.).13. Connect the rear stabilizer bar link and bushing to the rear stabilizer bar. Tighten the
5107

5 - 6 Nm (45 -14. Reposition the brake anti-lock sensor wires, and install the rear brake anti-lock sensors. Tighten the
53 inch lbs.).
15. Reposition the parking brake rear cable and conduits. Connect the parking brake rear cable and conduits to the rea
and install the retaining clip.
16. Connect the parking brake rear cable and conduits to the parking brake lever.
NOTE: Restore the tension to the parking brake rear cable and conduit.
115 - 142 Nm (85 - 105 ft. lbs.).
118 ml (4 oz)17. Install the rear disc brake rotor.18. Install the rear disc brake caliper.18. Install the wheel and tire ass
6 - 14 mm (1/4- 9/16 inch)
20 - 40 Nm (15 - 30 ft.lbs.). Additive Friction Modifier C8AZ- 1 913546-A or equivalent meeting Ford specifica
23. Road test vehicle.
> Transmission and Drivetrain > Differential Assembly > Drain Plug, Differential > Component Information > Specifications
Drain Plug: Specifications

Oil Filler Plug ......................................................................................................................................................................
> Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications
Fluid - Differential: Capacity Specifications

Note:
Fill no higher than 1/4 to 9/16 inch below fill plug.
Traction-Lok differentials add 4 oz of friction modifier C8AZ-19B956-A or equivalent, meeting Ford specification EST
> Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 5115
Fluid - Differential: Fluid Type Specifications

NOTE: Use the following fluids or an equivalent.
Rear Axle LubricantPart No. ...............................................................................................................................................

> Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Page 5116
Fluid - Differential: Service and Repair
1. Raise vehicle.2. Clean all dirt from area of axle housing cover.3. Drain rear axle lubricant by removing axle housin
4. Apply Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A or ESE-M4G1
38 - 52 Nm (28 - 38 ft. lbs.)and tighten axle housing cover bolts to .
CAUTION:
Make sure machined surfaces on both axle housing cover and rear axle housing are clean before installing the ne
NOTE: Axle housing cover must be installed within 15 minutes of the silicone rubber application or new silico
6 - 14 mm5. Add SAE 80W-90; Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specifica
(0.250 - 0.562 inch)
28 - 40 Nm (21 - 29 ft. lbs.) below bottom of fill hole. Add 118.2 ml (4 oz) of Additive Friction Modifier C8AZ-
> Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications
Pinion Bearing: Specifications

Differential Side Bearing Cap Bolts ....................................................................................................................................
Pinion Bearing Preload:

[1]
[2]Collapsible Spacer ......................................................................................................................................................
[1]
[2] If pinion bearing preload exceeds specification before this torque is obtained, install a new collapsible spacer. With
> Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications
Ring Gear: Specifications
Backlash Between RingGear and Pinion Teeth ...................................................................................................................

> Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Page 5123
Ring Gear: Testing and Inspection
TOOTH CONTACT PATTERNS CHECK OF GEAR SET

1. Set up ring gear to create a pattern as follows:
a. The final pinion position will be verified by using the gear contact pattern method described as follows:b. The
0.05 mm (0.002 inch) to 0.10 mm (0.004 inch)surface at the outer end. The top land of a gear tooth is the sur
0.10 mm (0.004 inch)

0.15 mm (0.006 inch)When a change in backlash is required, backlash shims should be changed in the range
High backlash is corrected by moving the ring gear closer to the pinion. Low backlash is corrected by moving
NOTE:
When making changes, note that two variables are involved. For example, if you have the backlash set corre
c. Paint ring gear teeth with a marking compound to both the drive and coast side.
2. While turning pinion gear, rotate ring gear one complete revolution in both directions. Apply load with a large scre
the carrier casting and differential case flange.
3. Interpret the pattern left on ring gear as shown in the following illustrations:
WARNING: GEAR TEETH MAY HAVE SHARP EDGES. WHEN HANDLING GEARS, USE CARE
-
Normal or desirable pattern. The drive pattern should be centered on the tooth. The coast pattern should be ce

- Backlash correct. Thinner pinion position shim required.
- Backlash correct. Thicker pinion position shim required.
- Pinion position shim correct. Decrease backlash.
- Pinion position shim correct. Increase backlash.
4. Pinion and ring gear movements can be adjusted to obtain satisfactory roll patterns as follows:
a. Decreasing backlash moves the ring gear closer to the pinion. Drive pattern (convex side of gear) moves slight
pattern (concave side of gear) moves lower and toward the toe.
b. Increasing backlash moves the ring gear away from the pinion.Drive pattern moves slightly higher and toward
higher and towards the heel.
c. Thicker pinion position shim with the backlash constant moves the pinion closer to the ring gear. Drive pattern
(flank contact) and slightly toward the toe. Coast pattern moves deeper on the tooth and toward the heel.
d. Thinner pinion position shim with the backlash constant moves the pinion farther from the ring gear. Drive pat
tooth (face contact) and toward the heel. Coast pattern moves toward the top of the tooth and slightly toward t
Ring Gear: Adjustments
Two separate adjustments affect pinion and ring gear tooth contact: pinion location and backlash.
Individual differences in matching the rear axle housing and the differential pinion bearings require the use of shims
> Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Inspection
Seals and Gaskets: Service and RepairInspection
When the rear axle drive pinion seal leaks, it may be that it was not installed properly, or because of rough texture or
Any damage to the seal bore (dings, dents, gouges or other imperfections) will distort the seal casing and allow leaka
The rear axle drive pinion seal can be torn, cut or gouged if it is not installed carefully with the correct service tool. T
The rubber lips can occasionally become hard (like plastic) with cracks at the oil lip contact point. The contact point
Metal chips or sand trapped at the sealing lip may also cause oil leaks. This can cause a wear groove on the rear axle
> Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Inspection > Page 5130
Seals and Gaskets: Service and RepairRemoval
REMOVAL
1. Raise the vehicle and install safety stands. Remove the rear wheels and rear disc brake rotors.
CAUTION: This operation disturbs the pinion bearing preload. Preload must be carefully reset when assembling
NOTE: Replacement of rear axle drive pinion seal involves removal and installation of only the pinion nut and r
2. Mark the driveshaft centering socket yoke and rear axle universal joint flange to make sure the driveshaft is proper
Disconnect the driveshaft from the rear axle universal joint flange. Remove the driveshaft from the transmission
NOTE: If rear axle universal joint flange is being replaced, it is not necessary to mark the driveshaft centering s
3. Install a Nm (inch lbs.) torque wrench on the pinion nut. Record the torque required to maintain rotation of the pin

4. While holding rear axle universal joint flange with Companion Flange Holding Tool 205-126 (T78P-4851-A), rem
6. Mark rear axle universal joint flange in relation to pinion shaft so rear axle universal joint flange can be installed i
7. Remove rear axle universal joint flange using Companion Flange Remover 205-018 (T65L-4851-13).
CAUTION:
To prevent damage to the rear axle universal joint flange or drive pinion bearing adjustment shim, never strike th
8. Position screwdriver under flange of rear axle drive pinion seal and carefully strike with hammer to wedge screwd
of rear axle drive pinion seal and rear axle housing.

CAUTION: Do not damage rear axle housing while removing rear axle drive pinion seal.
9. Pry up on metal flange of rear axle drive pinion seal. Install gripping pliers and strike with hammer until rear axle
INSTALLATION
1. Clean the flange yoke seal seat surface and install rear axle drive pinion seal on Pinion Seal Replacer 205-133 (T7
Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B between seal lips (if no
CAUTION:
Installation without proper tool may result in early rear axle drive pinion seal failure. If rear axle drive pinion sea
2. .Make sure splines on the pinion shaft are free of burrs. If burrs are evident, remove them by using a fine crocus cl
motion, wipe the pinion clean.
NOTE: Check rear axle universal joint flange for burrs. Remove burrs as necessary
3. Install rear axle drive pinion seal in to rear axle housing.4. Apply a small amount of Premium Rear Axle Lubrican
universal joint flange splines.
5. Align mark on rear axle universal joint flange with mark on the pinion shaft. Install rear axle universal joint flange

CAUTION: To prevent damage, the rear axle universal joint flange must never be hammered on or assembled w
6. Install a new pinion nut on pinion shaft (apply a small amount of Premium Rear Axle Lubricant XY-8OW90-QL o
specification WSP-M2C197-A on the washer side of nut).
7. Hold the rear axle universal joint flange with Companion Flange Holding Tool 205-126 (T78P-4851-A) while tigh
8. Tighten pinion nut. Rotate differential ring gear and pinion occasionally to make sure bearing seats properly. Take
bearing torque preload readings until the original recorded preload reading is obtained.
0.9 - 1.5 Nm (8 - 14 inch lbs.)8. If the original recorded preload is less than specification, tighten until a rotational to
the preload is higher than specification, tighten to original reading as recorded.Never back off the pinion nut to re
10. Remove Extension Housing Seal Replacer 308-002 (T61L-7657-A) from the transmission extension housing. Inst
on the transmission output shaft.
11. Connect the rear end of the driveshaft to the rear axle universal joint flange, aligning the marks on the driveshaft a
95 - 130 Nm (70 - 95 ft. lbs.).flange. Tighten rear axle universal joint flange bolts to
12. .Fill axle with Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C
6 - 14 mm (1/4 - 9/16 inch) 118 ml (4 oz)
20 - 40 Nm(15 - 29 ft. lbs.). below bottom of filler hole with the axle in operating position. Add of Additive Fri
CAUTION: Overfilling axle can cause rear axle housing vent or seal leakage
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair
Axle Bearing: Service and Repair
REMOVAL
1. Remove axle shafts.
2. Insert Rear Axle Bearing Remover 205-219 (T85L-1225-AH) in bore and position it behind rear wheel bearing so
outer race. Remove rear wheel bearing and inner wheel bearing oil seal as an assembly, using Impact Slide Hamm
INSTALLATION
1. Lubricate the rear wheel bearing with Premium Rear Axle Lubricant XY-80W90-OL or equivalent meeting Ford s
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Page 5138

2. Install rear wheel bearing into the housing bore using Axle Tube Bearing Replacer 205-124 (T78P-1225-A).
CAUTION:
Installation of rear wheel bearing or inner wheel bearing oil seal assembly without proper tool may result in an ea
3. Install the inner wheel bearing oil seal using Axle Tube Seal Replacer 205-123 (T78P-1177-A). Use Premium Lon
equivalent meeting Ford specification ESA-M1C75-B between the lips of the inner wheel bearing oil seal.
4. Install axle shafts.
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications
Axle Shaft: Specifications

Axle Shaft End Play .............................................................................................................................................................
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 5143
Axle Shaft: Service and Repair

NOTE:
Whenever replacing the rear axle lubricant, use SAE 8OW-90: Premium Rear Axle Lubricant XY-80W90-QL or equiv
REMOVAL
1. Raise vehicle to desired working height. Remove rear wheel and tire assembly. Remove rear disc brake calipers an
CAUTION:
The rear brake anti-lock sensor must be removed before the axle shafts are removed to prevent damage to the rea
2. Clean all dirt from area of axle housing cover with a wire brush or cloth.3. Drain rear axle lubricant by removing t
Rear Axle Removal
5. Push flanged end of the axle shaft toward the center of the vehicle and remove the U-washer and rear axle shaft O
axle shaft.

6. Remove axle shaft from the rear axle housing. Do not damage the inner wheel bearing oil seal and rear brake anti-
INSTALLATION
1. Carefully slide axle shaft into rear axle housing without damaging rear wheel bearing or rear brake anti-lock senso
differential side gear and push firmly until the button end of the axle shaft can be seen in the differential case.
CAUTION: Do not let splines on axle shaft damage oil seal or bearing assembly.
NOTE: Check for presence of rear axle shaft O-ring on the spline end of the s1haft and install if not present.
2. Install the U-washer on the button end of the axle shaft splines. Pull the shaft outboard until the U-washer seats in
differential side gear.
3. Position the differential pinion shaft through the differential case and differential pinion gears, aligning the hole in
20 - 41 Nm (15 - 30 ft. lbs.).the lock bolt hole. Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent m
CAUTION:
Differential pinion shaft lock pin must be tightened to specification using Stud and Bearing Mount EOAZ-19554
Rear Axle Removal

4. Apply Silicone Rubber D6AZ-19562-AA or BA or equivalent meeting Ford specification ESB-M4G92-A or ESE-
38 - 52 Nm (28 - 38 ft. lbs.)cover and tighten axle housing cover bolts to .
CAUTION:
Make sure machined surfaces on both axle housing cover and rear axle housing are clean before installing the new
NOTE: Axle housing cover must be installed within 15 minutes of application of the silicone rubber or new silic

6 - 14 mm (1/4 - 9/165. Add Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification
inch) 118.3 ml (4 oz)
20 - 40 Nm (15 - 30 ft. lbs.). below bottom of fill hole. Add of Additive Friction Modifier C8AZ-1913546-A or
5 - 7 Nm (44 - 62 inch lbs.).
6. Install rear brake anti-lock sensor. Tighten retaining bolt to 7. Install rear disc brake caliper and rear disc brake ro
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair
Seals and Gaskets: Service and Repair
Axle shaft inner wheel bearing oil seals are susceptible to the same kinds of damage as rear axle drive pinion seals if
Occasionally, the spiral machining lead on the axle shaft seal journal can cause an oil pumping action past the seal. I
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Pr
Article No.99-11-1
06/14/99
^
^
CONTENTS
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/
Vibration/Harshness Procedure > Page 5154

GENERAL PROCEDURES
Diagnostic Theory

Diagnostic Process

Glossary of Terms

Dynamic Balance







a.
c.
d.

-
Vibrate Software(R)

ChassisEAR
EngineEAR


Tracing Powder
d.

Diagnostic Process




2. Pre-Drive Check
important
^
^
^
^
5. Road Test
Note:
^

speed-related.
^
^
^

^

Steering Input Test
^
Brake Test
^
^
^
^

^ WARNING:
^ CAUTION:

^
WARNING:
CAUTION:
Note:
^
^ Start the engine.
^ CAUTION:

1. Static operation
^
2. While cranking
3. At idle
^
1.
1. Speed related
-
Idle vibration
-

-

-
-
Airvaries
Noise Leak with
wind/vehicle
2. Acceleration
-
4. Braking.
^
^
^
5. Clutching

6. Shifting
^
8. Cruising speeds
1.




































Pinpoint Tests































1. Open the hood.
2. Note:
Note:
4.
3. CAUTION:

3.
6.
7.

^



WARNING:
4. CAUTION:

WARNING:
WARNING:
Note:
1. WARNING:

CAUTION:
6.
^

Wheel Bearing Check
1. WARNING:

2. Note :

^
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Page 5249

-
-
-
REMOVAL

INSTALLATION
255-345 Nm (189-254 ft. lbs.).
200 Nm (147 ft. lbs.).

> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications

> Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Companion Flange > Component Information > Testing and Inspection
Companion Flange: Testing and Inspection
1. Raise the vehicle on a hoist that supports the rear axle (twin post hoist).2. Remove the driveshaft assembly.3. Insp
4. Position Companion Flange Runout Gauge 205-319 (T92L-4851-B) on rear axle universal joint flange.
5. Install Clamp Plate 205-320 (T92L-4851-C) on runout gauge.
> Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Companion Flange > Component Information > Testing and Inspection > Page 5263

6. Align holes in clamp plate with holes in rear axle universal joint flange and install bolts. Snug bolts evenly.
7. Using Dial Indicator/ Magnetic Base 100-DO02 (D78P-420 1-B) or equivalent, turn Companion Flange Runout G
0.254 mm (0.010 inch)
0.254 mm (0.010 inch)
as shown to locate and mark high spot on rear axle universal joint flange. If flange runout exceeds , remove rear a
CAUTION:
This operation disturbs the pinion bearing preload. Pinion bearing preload must be reset if the pinion nut has bee
8. If excessive runout is still evident after replacement of the rear axle universal joint flange, replace the differential r
95 - 130 Nm (70 - 95 ft. lbs.)above checks until runout is within specifications. Install the driveshaft assembly. T
> Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications
Drive/Propeller Shaft: Specifications
Driveshaft to Rear Axle U-Joint Flange Bolts .....................................................................................................................

> Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 5267
> Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 5268
Drive/Propeller Shaft: Description and Operation

NOTE:
All driveshaft assemblies are balanced. If the vehicle is to be undercoated, cover the driveshaft, universal joints and
Thetwo single cardan

driveshaft universal
is a tubular shaftjoints
used to transfer engine torque from the transmission output shaft to the differential in
- a driveshaft slip yoke
- a welded aluminum tube assembly
- driveshaft centering socket yoke
The driveshaft slip yoke permits the driveshaft to move forward and rearward on the transmission output shaft during
> Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Adjustments > Driveshaft Balancing
Drive/Propeller Shaft: AdjustmentsDriveshaft Balancing
Vibration or shudder which is noticeable either on fast acceleration, when coasting or when using the engine for brak
line speed.
64 - 80 km/h (40-50 mph)3. With the transmission in gear, run the vehicle with the driveshaft rotating at a speed of
bring a crayon, piece of chalk or colored pencil up until it just barely contacts the rear end, center and front end o
WARNING: USE CAUTION WHEN CHECKING THE DRIVESHAFT NEAR THE BALANCE WEIGH
4. Install two screw-type hose clamps on the driveshaft so their heads are located 180 degrees from the chalk mark, s
joint flange end of the driveshaft. Tighten the clamps.
> Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Adjustments > Driveshaft Balancing > Page
5271

5. Accelerate the vehicle up to the base line speed. If vibration is still evident, rotate the clamps approximately 45 de
for correctness of vibration.
CAUTION:
Do not run the engine on the hoist with the transmission engaged for extended periods due to the danger of over
6. If necessary, continue to rotate the clamps apart in smaller increments until the vibration becomes reduced or elim
reduction of the vibration.
8. Remove the vehicle from the hoist and perform a road test.
> Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Adjustments > Driveshaft Balancing > Page 5272
Drive/Propeller Shaft: AdjustmentsAlternate Procedure
1. Road test - evaluate and record road speed at which vibration occurs.2. Raise vehicle on a frame contact hoist. Re-
which the vibration was most severe during the road test. Suspending the rear axle makes the driveline more sens
3. Mark one of the driveshaft centering socket yoke mounting bolt holes A, and number the rear axle universal joint f
with the one mating with A. The original position can then be identified as A-1. Re-index the shaft 180 degrees to
4. A vehicle is more sensitive to excessive imbalance or runout at the rearward end of the driveshaft; therefore, locat
by using the strobe light and transducer from Rotunda Electronic Strobe Balancer 006-01400 or equivalent as fol
dislodging.
101.6 mm (4 inches)c. Draw an axial chalk line axial radial location approximately long at the rear of the drives
> Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Adjustments > Driveshaft Balancing > Page
5273

d. Locate the transducer on the bottom side of the rear axle housing and secure it in place.e. Run the engine at the
for the initial location of the clamps.
5. Stop the engine and rotate the driveshaft so the chalk line is in the same location as seen under the strobe light.
6. Install two stainless steel hose clamps on the driveshaft. Position the clamp heads 180 degrees from the transducer
correct position and go to Step 9.
CAUTION:
Do not run the engine on the hoist with the transmission engaged for extended periods due to the danger of over
However, if any vibration still exists, the combined weight of the two hose-clamp heads may be in excess. To
8. Continue to rotate the clamp heads apart in smaller angular increments until the vehicle feel of balance (vibration)
If satisfactory
wheels improvement
and tires and has
road test the been obtained,
vehicle proceed
to determine to Step
the actual 9. of improvement.-
degree
9. When the balance has been corrected to a satisfactory level, tighten the clamps securely.
> Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Adjustments > Page 5274
Drive/Propeller Shaft: Service and Repair

REMOVAL
1. To maintain driveline balance, index mark the driveshaft centering socket yoke and rear axle universal joint flange
their original positions.
2. Remove the four driveshaft centering socket yoke bolts and disconnect the driveshaft from the rear axle universal
toward the rear of the vehicle until the driveshaft slip yoke clears the transmission extension housing and seal. M
INSTALLATION
1. Lubricate the driveshaft slip yoke splines with Premium Long-Life Grease XG-1-C or -K or equivalent meeting Fo
Remove the plug from the transmission extension. Inspect the housing seal for damage; replace if required.
2. Align driveshaft slip yoke index mark with the transmission output shaft mark and install the driveshaft . Do not a
assembly to bottom on the output shaft with excessive force.
3. Install and align the driveshaft so the index mark on the driveshaft centering socket yoke is in-line with the index m
joint flange. This maintains original driveline balance.
NOTE:
When installing a new driveshaft, align the factory-made yellow paint mark at the rear of the driveshaft tube wit
95 - 130 Nm (70 - 96 ft. lbs.).4. Tighten the four driveshaft centering socket yoke bolts to
> Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Adjustments > Page 5275
Special Tools
> Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Diagrams
> Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Diagrams > Page 5279
Universal Joint: Description and Operation
Measurements made with bearing cups fully seated.
NOTE: Span measurements are made with bearing cups fully seated on spider.
92.07 mm (3 5/8 inch) 26.98 mm (1 1/16 inch)Vehicles are equipped with 1330 Series universal joints with a span
NOTE: Other type universal joints should not be used in place of this type. Driveshaft imbalance and vibration can
Thelubed-for-life design. joints are:-

driveshaft universal
-
equipped with nylon thrust washers, located at each base of the bearing cup, which control end play, position the
Universal Joint: Testing and Inspection
1. Remove driveshaft.2. Manipulate universal joint in each direction of rotation. If U-joint feels stiff or has a lumpy o
Universal Joint: Service and Repair

DISASSEMBLY
CAUTION:
Under no circumstance is the driveshaft assembly to clamped in the jaws of a vise or similar holding fixture. Dentin
1. Place driveshaft on a suitable work bench. Be careful not to damage tube.2. Prior to disassembly, mark the positio
same relationship to maintain proper balance.
3. Clamp U-Joint Tool 205-086 (T74P-4635-C) in vise.4. Remove the four snap rings that retain the bearing cups.
5. Position the driveshaft slip yoke in U-Joint Tool 205-086 (T74P-4635-C) and press out bearing cup. If bearing cup
out of the driveshaft slip yoke, remove it with vise grip or channel-lock pliers.
6. Reposition the driveshaft slip yoke in U-Joint Tool 205-086 (T74P-4635-C) 180 degrees to press on the spider and
cup from the opposite side.
7. Remove driveshaft slip yoke from the spider, clean all foreign matter from driveshaft slip yoke.8. Remove the rem
ASSEMBLY

NOTE: Universal joint service kits are to be installed as complete assemblies only. Do not mix components from ot
1. Start a new bearing cup into the yoke of the driveshaft .
6.3 mm (1/4 inch)2. Position the new spider in the driveshaft yoke and press the bearing cup below the yoke surface
(T74P-4635-C).
3. Remove U-Joint Tool 205-086 (T74P-4635-C) and install a new snap ring.4. Start a new bearing cup into the oppo
6. Remove the driveshaft from U-joint tool and install a new snap ring. Check snap ring for proper seating.
NOTE:
Assemble the universal joint using the yellow snap rings supplied in the kit. If difficulty is encountered with yel
7. Install the driveshaft slip yoke, remaining bearing cups, spider and snap rings in the same manner.

8. Check the universal joints for freedom of movement. If binding has resulted from misalignment during assembly,
yoke with a brass or plastic hammer will seat bearing cups. Take care to support the shaft end and do not strike th
> Transmission and Drivetrain > Flex Plate > Component Information > Specifications
Flex Plate: Specifications

Flywheel to Crankshaft Bolt ............................................................................................................................................

> Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 5287
Flex Plate: Testing and Inspection
Inspect the flywheel for cracks or other damage that would make it unfit for further service. Inspect the flywheel ring g
> Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 5288
Flex Plate: Service and Repair

REMOVAL
1. Remove transmission.2. Remove six bolts retaining flywheel to crankshaft and remove flywheel.
INSTALLATION
73-87 Nm (54-64 ft. lbs.).
1. Position flywheel on crankshaft and install six retaining bolts. Tighten in alternating sequence to 2. Check flywhe
> Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments
1.4 kg (3 lbs.)
adjustment.
> Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments > Page 5294

REMOVAL
INSTALLATION
> Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Servic
Assembly

DISASSEMBLY
forward.
range indicator.
ASSEMBLY
> Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Servic
Assembly > Page 5299

REMOVAL
INSTALLATION
> Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Ha
Article No.99-11-1
06/14/99
^
^
CONTENTS
> Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive

GENERAL PROCEDURES
Diagnostic Theory

Diagnostic Process

Glossary of Terms

Dynamic Balance







a.
c.
d.

-
Vibrate Software(R)

ChassisEAR
EngineEAR


Tracing Powder
d.

Diagnostic Process




2. Pre-Drive Check
important
^
^
^
^
5. Road Test
Note:
^

speed-related.
^
^
^

^

Steering Input Test
^
Brake Test
^
^
^
^

^ WARNING:
^ CAUTION:

^
WARNING:
CAUTION:
Note:
^
^ Start the engine.
^ CAUTION:

1. Static operation
^
2. While cranking
3. At idle
^
1.
1. Speed related
-
Idle vibration
-

-

-
-
Airvaries
Noise Leak with
wind/vehicle
2. Acceleration
-
4. Braking.
^
^
^
5. Clutching


6. Shifting
^
8. Cruising speeds
1.




































Pinpoint Tests































1. Open the hood.
2. Note:
Note:
4.
3. CAUTION:

3.
6.
7.

^



WARNING:
4. CAUTION:

WARNING:
WARNING:
Note:
1. WARNING:

CAUTION:
6.
^

Wheel Bearing Check
1. WARNING:

2. Note :

^
> Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operat
> Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Control Switch <--> [Overdrive Switch, A/T] > Compone
Operation

(PCM)
(TCIL)
OPERATION
TheThe system
range engages
transmission mode
control switch each
in the time
shift theknob.-
-
> Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service B
Article No.02-13-6
07/08/02
ISSUE
ACTION
Parts Block

BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
> Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information >
Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 5418

3.
> Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Technical Service B
Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative
Article No.02-13-6
07/08/02
ISSUE
ACTION
Parts Block

BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
> Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 5424

3.
> Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams

> Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range (TR) Sensor <--> [Transmission Position S
Transmission View


7 - 10 Nm (62 - 88 inch lbs.).
19 - 26 Nm (14 - 19 ft. lbs.)
REMOVAL
INSTALLATION
(TR)
7 - 10 Nm (62-88 inch lbs.)
19 - 26 Nm (14 - 19 ft. lbs.)
> Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifica

Transmission View

REMOVAL
(VSS)
INSTALLATION
7 - 10 Nm (62 - 88 inch lbs.)

> Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Comp

> Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Comp
Page 5447

REMOVAL
CAUTION:
INSTALLATION
13 - 17 Nm (10 - 12 ft. lbs.)
13 - 17 Nm (10 - 12 ft. lbs.)
> Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Componen
REMOVAL

CAUTION:
> Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/
T > Component Information > Service and Repair > Page 5451

NOTE:
spring.
NOTE:

INSTALLATION

11 - 15 Nm (98 - 132 inch lbs.)
26 - 37 Nm (20 - 27 ft. lbs.)


7 - 10 Nm (62 - 88 inch lbs.).

19 - 26 Nm (14 - 19 ft. lbs.).
> Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Soleno
Specifications

> Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Informat
1.4 kg (3 lbs.)
adjustment.
> Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Informat

REMOVAL
INSTALLATION
> Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T >
Repair > Disassembly and Assembly

DISASSEMBLY
forward.
range indicator.
ASSEMBLY
> Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T >
Repair > Disassembly and Assembly > Page 5468

REMOVAL
INSTALLATION
> Transmission and Drivetrain > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Info
> Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Control Switch <--> [Ov
Information > Description and Operation

(PCM)
(TCIL)
OPERATION
TheThe system
range engages
transmission mode
control switch each
in the time
shift theknob.-
-
> Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component I
Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative
Article No.02-13-6
07/08/02
ISSUE
ACTION
Parts Block

BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
> Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock -

3.
> Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component I
Bulletins > Customer Interest for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative
Article No.02-13-6
07/08/02
ISSUE
ACTION
Parts Block

BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
> Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch
> Component Information > Technical Service Bulletins > Customer Interest for Shift Interlock Switch: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page
5493

3.
> Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Co

> Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range (TR) Sen
Switch/Sensor, A/T] > Component Information > Locations
Transmission View

Switch/Sensor, A/T] > Component Information > Locations > Page 5500

7 - 10 Nm (62 - 88 inch lbs.).
19 - 26 Nm (14 - 19 ft. lbs.)
REMOVAL
INSTALLATION
(TR)
7 - 10 Nm (62-88 inch lbs.)
19 - 26 Nm (14 - 19 ft. lbs.)
> Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Co

> Page 5507
Transmission View
> Page 5508

> Page 5509
REMOVAL
(VSS)
INSTALLATION
7 - 10 Nm (62 - 88 inch lbs.)

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation
ABS Light: Description and Operation

The anti-lock brake system uses two warning indicators (BRAKE and ABS) to alert the driver of concerns in the sys
The BRAKE warning indicator will come on for only two reasons:1. If the brake fluid level in the brake master cylin
The amber ABS warning indicator will come on for numerous reasons. It warns the driver that the ABS and traction
Follow the diagnostic procedures step-by-step in order as indicated.Each test is completely independent of the other
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation > Page 5515
ABS Light: Testing and Inspection

For testing procedures for this component, refer to Instrument Panel, Gauges and Warning Indicators, Instrument Clust
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Diagrams

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interes
: > 98-19-7 > Sep > 98 > Engine - Hesistation When Accelerating
Article No.98-19-7
09/28/98
ISSUE
ACTION
NOTE
SERVICE PROCEDURE
2.

4.
NOTE
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins >
Customer Interest for Electronic Brake Control Module: > 98-19-7 > Sep > 98 > Engine - Hesistation When Accelerating > Page 5527

DEALER CODING
CONDITION
BASIC PART NO. CODE
2C219 42
OASIS CODES: 301000, 607000, 607500, 611000, 611500, 614000, 614500

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Se
Control Module: > 98-19-7 > Sep > 98 > Engine - Hesistation When Accelerating
Article No.98-19-7
09/28/98
ISSUE
ACTION
NOTE
SERVICE PROCEDURE
2.

4.
NOTE
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Electronic Brake Control Module: > 98-19-7 > Sep > 98 > Engine - Hesistation When Accelerating > Page 5533

DEALER CODING
CONDITION
BASIC PART NO. CODE
2C219 42
OASIS CODES: 301000, 607000, 607500, 611000, 611500, 614000, 614500

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5534


Engine View

(HCU).
-
- (DTC)

REMOVAL
INSTALLATION

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications
Hydraulic Control Assembly - Antilock Brakes: Specifications
Retaining Nuts .....................................................................................................................................................................

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 5542
EVAC And Fill Connector

Hydraulic Control Assembly - Antilock Brakes: Description and Operation
TheBrake
HCU pressure control
consists of valve block.
the following components:-
- Pump motor.
Duringof
Operation normal braking,
the HCU is as fluid passes through four normally open inlet valves, one to each wheel.
follows:-
-
If the anti-lock brake control module senses a wheel is about to lock, it pulses the appropriate inlet valve which c
-
The anti-lock brake control module then looks at that wheel again. If it is still decelerating, it opens the closed ou
-
The traction control portion of the brake pressure control valve block contains two isolation valves for traction co
The brake pressure control valve block and pump motor are replaced as an assembly.
Hydraulic Control Assembly - Antilock Brakes: Service and Repair

REMOVAL
(ACL)
1. Disconnect battery ground cable.2. Remove engine Air Cleaner and air cleaner outlet tube.3. Disconnect 25-pin c
4. Remove the two inlet brake tubes and the three anti-lock outlet brake tubes, or the four anti-lock traction control b
control module. Plug each port to prevent brake fluid from spilling on paint and wiring.
5. Remove the three 13 mm bolts retaining the hydraulic control unit to the mounting bracket. Remove hydraulic con
INSTALLATION
16 - 24 Nm (12 - 17 ft. lbs.)
1. Make sure hydraulic control unit is fully seated in bracket. Install the three retaining bolts. Tighten to .2. Connect
14 - 24 Nm (11 - 17 ft. lbs.)control module and two tubes to inlet ports on top of the hydraulic control module. T
3. Connect 25-pin connector to anti-lock brake control module.4. Install engine air cleaner and air cleaner outlet tube
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 5549

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Front
Part 1 Of 2
Part 2 Of 2
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Front > Page 5552
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 5553
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring
Front Axle
Rear Axle
REMOVAL
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page
5556

CAUTION:
INSTALLATION
5557


5558

> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 5559
Front
Part 1 Of 2
Part 2 Of 2
REMOVAL
INSTALLATION
5 - 6 Nm (45 - 53 inch lbs.)
Rear
5560

REMOVAL
INSTALLATION
5 - 6 Nm (45 - 53 inch lbs.)
> Brakes and Traction Control > Brake Bleeding > System Information > Service Precautions
> Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure
Repeat
bleeder comes out.
screw.-
> Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 5566
NOTE:
of a turn.
CAUTION:
(NGS)
trouble codes.
- Select ABS Module
> Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications
Brake Pedal Assy: Specifications
Brake Pedal To Booster Nuts ...............................................................................................................................................

> Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 5573
> Brakes and Traction Control > Brake Pedal Assy > Component Information > Adjustments > Brake Pedal Height
Brake Pedal Assy: AdjustmentsBrake Pedal Height
1. With the engine running for full power brake operation and the parking brake fully released, measure the brake pe
accelerator pedal side of the brake pedal pad.
3. If the position of the brake pedal is not within specification, check the brake pedal for missing, worn or damaged b
and replace if required.
4. If the brake pedal free height is still out of specification, check the brake pedal, power brake booster or brake mast
parts are installed. Replace the worn or damaged parts as necessary.
NOTE:
"A" Dimension
Travel to be with
Test to be made measured to sheet
parking brakemetal from center
in released of pad on the accelerator pedal side of the brake pedal
position.-
-
"B" Dimension to be measured parallel to the vertical center line of the steering column with a 111.2 N (25 lbs.) l
> Brakes and Traction Control > Brake Pedal Assy > Component Information > Adjustments > Brake Pedal Height > Page 5576
Brake Pedal Assy: AdjustmentsBrake Pedal Travel

1. With engine running and transmission in PARK or NEUTRAL, block wheels and release parking brake control.
2. Install the Rotunda Brake Pedal Gauge 014-R1051 or equivalent on the brake pedal and check.
3. Hook a steel measuring tape to the brake pedal. Measure and record the distance from the brake pedal free height p
which is at the six o'clock position on the steering wheel rim.
4. With the steel tape still hooked to the brake pedal, apply the brake pedal by pressing downward on the brake pedal
(25 lbs.) load to the center of the brake pedal. Maintain the brake pedal load and measure the distance from the br
5. The difference between the brake pedal free height measurement and the depressed pedal measurement under a 11
mm (3.5 inches) maximum.
6. If the brake pedal travel is more than the maximum dimension specification, inspect the front and rear brakes for s
damage and correct installation. Service as necessary.
7. If the above steps do not bring the brake travel within specification, bleed the brake system.
> Brakes and Traction Control > Brake Pedal Assy > Component Information > Adjustments > Page 5577
Brake Pedal Assy: Service and Repair
Brake Pedal And Bracket Components/Description
REMOVAL
1. Disconnect battery ground cable.2. Disconnect the stoplight switch wire connector from the stoplight switch.3. Lo
cylinder push rod spacer. Slide the stoplight switch outboard along the brake pedal pin just far enough for the out
4. Slide the push rod off the pedal pin.5. Remove the prevailing torque nut and then remove the pivot bolt, brake ped
push rod bushing from the pedal support bracket.
INSTALLATION
1. Apply a coating of clean engine oil meeting Ford specification WSS-M2C910-A1 to the brake master cylinder pus
and brake pedal support mounting spacer in the brake pedal hub.
2. Position the brake pedal as an assembly in the pedal support bracket and install the pivot bolt. Install the prevailing
14 - 27 Nm (10 - 20 ft. lbs.).
3. Install the brake master cylinder push rod and the brake master cylinder push rod bushing on the brake pedal pin. P
that it straddles the push rod with the slot on the pedal pin and the switch outer frame hole just clearing the pin. S
21 - 29 Nm (16 - 21 ft. lbs.)
4. Tighten the booster retaining nuts to .5. Connect the stoplight switch wire to the stoplight switch.6. Connect batter
> Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Front
Brake Caliper: SpecificationsFront
Torque Specifications:
Caliper Locating Pin Retainer (tighten bottom pin first)............................................................................................

> Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Front > Page 5583
Brake Caliper: SpecificationsRear
Caliper Bleeder Screw ................................................................................................................................................

> Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Page 5584
> Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Description and Operation > Brake Caliper
Brake Caliper: Description and OperationBrake Caliper
Front
Theare pin
disc slider-type
brake with phenolic caliper pistons, piston seals and press-in type dust boots.
calipers:-
- are mounted to a front disc brake caliper anchor plate which in turn mounts to the front wheel spindle.
- slide-on lubricated disc brake caliper locating pins that are sealed for life from the elements by rubber boots.
Rear
Thesteel
rear rear
disc disc
brakebrake piston.
caliper assembly consists of:-
- rubber O-ring seal positioned in a groove in the rear disc brake caliper housing.
- press-in type dust boot.
> Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Description and Operation > Brake Caliper > Page 5587

RearRear
discdisc brake
brake caliper
caliper is attachedastofollows:-
is assembled the rear wheel disc brake adapter by two hex head disc brake caliper bolts.
- Rubber insulators isolate the disc brake caliper locating pins from the rear disc brake caliper.
> Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Description and Operation > Brake Caliper > Page 5588
Brake Caliper: Description and OperationBrake Caliper Bracket
Thetransmits braking
rear wheel torque
disc brake from the inner and outer rear brake pads and linings to the rear axle housing.
adapter:-
- provides a mounting for the parking brake assembly.
> Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Testing and Inspection > Front
Brake Caliper: Testing and InspectionFront

1. Clean all metal parts with isopropyl alcohol. Then, clean out and dry the grooves and passageways with compresse
brake caliper bore and component parts are thoroughly clean.
2. Check cylinder bore and caliper pistons for damage or excessive wear. Replace a caliper piston if it is pitted, score
worn off.
3. Visually check disc brake caliper. If caliper housing is leaking, it should be replaced. If a seal is leaking, disc brak
and new seals and dust boots installed. If caliper piston is seized in the bore, a new disc brake caliper is required.
4. Inspect locating pin boots in front disc brake caliper anchor plate to make sure they are sealed in groove. Replace
boots that are not properly sealed may cause disc brake caliper locating pin to corrode and brakes to drag.
> Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Testing and Inspection > Front > Page 5591
Brake Caliper: Testing and InspectionRear
Clean all metal parts with isopropyl alcohol. Then clean out and dry grooves and passageways with compressed air. M
> Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front
Brake Caliper: Service and RepairFront

DISASSEMBLY
1. Remove disc brake caliper.2. Apply air pressure to the fluid port of disc brake caliper to remove caliper pistons us
CAUTION:
Use a wooden block or layers of shop towels to cushion possible impact of the wheel caliper pistons against the
3. Remove and discard the dust boots from the front disc brake caliper assembly.4. Remove and discard the rubber p
ASSEMBLY
1. Clean and inspect
- Remove the debris.
dirt and caliper pistons and the disc brake caliper.
- Examine the caliper pistons for surface irregularities, scoring or wear. Replace damaged caliper pistons.
- Clean the caliper bores with Metal Parts Brake Cleaner F5AZ-2C410-AA or equivalent meeting Ford specific
- If the caliper bores are corroded or excessively scored, replace the disc brake caliper.
- Lubricate the caliper pistons and piston seals before assembly.
CAUTION: Do not hone the caliper bores. Caliper pistons are not available for honed caliper bores.
2. Install new piston seal and dust boot.
3. Start caliper pistons into caliper bores by hand to assure correct alignment.
> Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5594

CAUTION: Make sure wheel caliper pistons are not cocked.
4. Install new bleeder screw and bleeder screw cap.5. Make sure dust boot is tight in boot groove on wheel caliper pi
Brake Caliper: Service and RepairRear

DISASSEMBLY
1. Remove rear disc brake caliper assembly. Remove outer rear brake pad and lining by slipping down caliper leg un
inner rear brake pad and lining by pulling it straight out of piston.
2. Apply air pressure to the fluid port in the rear disc brake caliper with Rubber-Tipped Air Gun 100-D009 or equiva
piston. If the rear disc brake piston is seized and cannot be forced from rear disc brake caliper, rear disc brake cal
CAUTION:
Do not use a screwdriver or any similar tool to pry rear disc brake piston out of bore. It will result in damage to
ASSEMBLY
1. When assembling rear disc brake caliper, examine rear disc brake piston for surface irregularities. Replace caliper
clean foreign material from piston surfaces and lubricate with brake fluid before inserting into rear disc brake cal
Retracting Caliper
2. When installing caliper piston back into bore, use a wood block or another flat stock, like an old rear brake pad an
C-clamp and caliper piston.
CAUTION: Do not apply C-clamp directly to piston surface. This can result in damage to caliper piston. Be sur
3. Make sure dust boot is tight in boot groove on caliper piston and in rear disc brake caliper.4. To install inner rear b
piston. Push firmly until pad clip snaps into piston. Do not allow pad or clip tangs to cock during installation.
5. Install rear disc brake caliper.
Brake Caliper: Service and RepairRemoval and Installation
Front
REMOVAL
1. Raise vehicle on hoist.2. Remove the wheel and tire assembly. Use care to avoid damage to, or interference with, t
4. Remove flow bolt that connects hose to disc brake caliper. Remove hose from caliper and plug hose.5. Remove tw
worn or damaged parts.
INSTALLATION
1. Use a 10 cm (4-inch) C-clamp and wood block or used brake pad to seat the caliper pistons in the bores. This mus
for the disc brake caliper to fit over the brake pads during installation.
2. Install replacement disc brake caliper or correct disc brake caliper as marked during removal, with the brake pads
disc brake caliper over front disc brake rotor.
3. Install two new caliper bolts.
Inspect disc brake caliper locating pin and locating pin boots.
NOTE:
It is important to use correct length bolts.
-- Install lower bolt first.
4. Remove plug and install front brake hose on disc brake caliper with new sealing washers on each side of the fitting
40 - 60 Nm (30 - 44 ft. lbs.)and washers. Tighten to .
5. Bleed serviced caliper.6. Install wheel and tire assembly, using Rotunda Accutorq - Lug Nut Sockets 164-R0303 o
115 - 142 Nm (85 - 104 ft. lbs.)wrench to tighten lug nuts to .
CAUTION:
Failure to tighten lug nuts in a star pattern can result in high rotor runout, which will speed up the development
7. Lower vehicle.8. Pump brake pedal several times to position brake pads and linings. Refill brake master cylinder r
Vehicle Brake Fluid C6AZ-19542-AB or DOT-3 equivalent meeting Ford specification ESA-M6C25-A as neces
Caliper

REMOVAL
1. Raise vehicle on hoist.2. Remove wheel and tire assembly.3. Disconnect flexible rear brake hose from rear disc br
caliper fitting.
4. Remove disc brake caliper bolts.5. Lift rear disc brake caliper off rear wheel disc brake adapter using a rotating m
INSTALLATION
Retracting Caliper
1. Retract caliper piston fully in piston bore and position rear disc brake caliper assembly above rear disc brake rotor
on upper adapter support arm. Install rear disc brake caliper over rear disc brake rotor with rotating motion. Make
CAUTION: Do not pry directly against caliper piston or damage to caliper piston will occur.
2. Install disc brake caliper bolts. Clean inner surface of caliper bushings and lubricate disc brake caliper bolts with S
and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A.
CAUTION: The disc brake caliper bolts must be inserted and started by hand.
22 - 27 Nm (17 - 20 ft. lbs.)

3. Tighten disc brake caliper bolts to .4. Remove plug and install rear brake hose on rear disc brake caliper with new
40 - 54 Nm (30 - 39 ft. lbs.)washers and fittings. Tighten bolts to .

5. Bleed serviced caliper. Always replace rubber rear disc brake bleeder screw cap after bleeding.6. Fill brake master
7. Install wheel and tire assembly, using Rotunda Accutorq Lug Nut Sockets 164-R0303 or equivalent on 1/2 inch dr
CAUTION:
Failure to tighten lug nuts in a star pattern may result in high rotor runout, which will speed up the development
8. Pump brake pedal prior to moving vehicle to position rear brake pads and linings.9. Road test vehicle.
Support Bracket
REMOVAL
1. Raise vehicle on hoist.2. Remove rear disc brake rotor and rear disc brake caliper. 3. Remove axle shaft.4. Remov
INSTALLATION
61 - 75 Nm (45 - 55 ft. lbs.)
1. Position rear wheel disc brake adapter on rear axle housing.2. Install four caliper anchor plate mounting bolts and
> Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest for Brake Pad: > 98-13-4 > Jul > 98 > Brakes -
Wet Brakes
Brake Pad: Customer InterestBrakes - Pull Or Drift When Braking With Wet Brakes
Article No.98-13-4
07/06/98
BRAKES - PULL OR DRIFT WHEN BRAKING WITH WET BRAKES
ISSUE
Drift or pull to the left or right during braking with wet brakes may be evident on some vehicles generally under rainy c
ACTION
Replace the front brake linings with revised linings which are less sensitive to water. Refer to the Service Procedure for
NOTE
REFER TO THE 1998 CROWN VICTORIA/GRAND MARQUIS OR TOWN CAR WORKSHOP MANUAL, SE
SERVICE PROCEDURE
1.
Check the vehicle tire pressures. Correct inflation of the front and rear tires is 220 kPa (32 psi). Incorrect or unev
2.
Replace the front brake linings with revised Brake Linings (F8AZ-2001-CA). Refer to the Workshop Manual, Se
NOTE

F8AZ-2001-CA Front Brake Linings
981304A Check Tire Pressure, 1.0 Hr.

Replace Front Brake Linings
DEALER CODING
CONDITION
DO NOT
BASIC PARTRESURFACE
NO. THE BRAKE ROTORS
CODE WHEN REPLACING THE WET BRAKE LININGS. WET PUL
2001 42
OASIS CODES: 301000, 303000

> Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 98-13-4 > Jul >
Braking With Wet Brakes
Brake Pad: All Technical Service BulletinsBrakes - Pull Or Drift When Braking With Wet Brakes
Article No.98-13-4
07/06/98
BRAKES - PULL OR DRIFT WHEN BRAKING WITH WET BRAKES
ISSUE
Drift or pull to the left or right during braking with wet brakes may be evident on some vehicles generally under rainy c
ACTION
Replace the front brake linings with revised linings which are less sensitive to water. Refer to the Service Procedure for
NOTE
REFER TO THE 1998 CROWN VICTORIA/GRAND MARQUIS OR TOWN CAR WORKSHOP MANUAL, SE
SERVICE PROCEDURE
1.
Check the vehicle tire pressures. Correct inflation of the front and rear tires is 220 kPa (32 psi). Incorrect or unev
2.
Replace the front brake linings with revised Brake Linings (F8AZ-2001-CA). Refer to the Workshop Manual, Se
NOTE

F8AZ-2001-CA Front Brake Linings
981304A Check Tire Pressure, 1.0 Hr.

Replace Front Brake Linings
DEALER CODING
CONDITION
DO NOT
BASIC PARTRESURFACE
NO. THE BRAKE ROTORS
CODE WHEN REPLACING THE WET BRAKE LININGS. WET PUL
2001 42
OASIS CODES: 301000, 303000

> Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Page 5612
Brake Pad: Specifications
Front Rear
Minimum Thickness 0.039 in 0.039 in

> Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Description and Operation > Front
Brake Pad: Description and OperationFront
Theslide
brakeinpads
the front disc brake caliper anchor plate
and linings:-
- use a single disc brake pad anti-rattle clip to prevent brake pad rattle
> Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Description and Operation > Front > Page 5615
Brake Pad: Description and OperationRear
TheThe
rearinner
brakerear
padbrake pads and
and lining linings are
assemblies haveinterchangeable left to right and use a three-finger clip that fits inside th
the following characteristics:-
-
The outer rear brake pads and linings are interchangeable left to right and use a dual-purpose clip which holds the
- The flanges on both inner and outer rear brake pads and linings slide on machined surfaces.
- The original equipment rear brake pad and lining contains no asbestos.
> Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Testing and Inspection > Front
Brake Pad: Testing and InspectionFront

1.0 mm (0.039 inch)
Inspect brake pads for excessive wear. If lining is worn to within of pad, replace all four brake pads (complete axle s
Replace any brake pad that has been contaminated with oil, grease, or brake fluid with a complete axle set. Inspect fo
> Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Testing and Inspection > Front > Page 5618
Brake Pad: Testing and InspectionRear
1.0 mm (0.039 inch)1. Remove wheel and tire assembly from rear hub and rear disc brake rotor.2. Inspect rear brake
> Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front
Brake Pad: Service and RepairFront

REMOVAL
1. Check fluid level in brake master cylinder reservoir. Remove brake fluid until brake master cylinder reservoir is ha
NOTE: It is not necessary to disconnect hydraulic connections.
5. Lift disc brake caliper away from front disc brake rotor using a rotating motion.
6. Remove outer and inner brake pad and lining from the front disc brake caliper anchor plate.7. Remove the pad slip
replacement of the front disc brake rotor.
INSTALLATION
1. Use a C-clamp and wood block or used brake pad to seat caliper pistons in the caliper bores. This must be done to
caliper assembly to fit over front disc brake rotor during installation.
> Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5621

NOTE: Make sure to use all parts supplied with the brake pads.
28 - 6 Nm (21 - 26 ft. lbs.)2. Install the pad slippers.3. Install the brake pads in the front disc brake caliper anchor pl
28 - 36 Nm (21 - 26 ft. lbs.)upper bolt to .
5. Make sure disc brake pad anti-rattle spring and disc brake pad anti-rattle clip is seated in caliper lining inspection
anti-rattle clip must be installed from the lining side.
6. Inspect disc brake caliper / front disc brake caliper anchor plate assembly to make sure brake pads and linings are
Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specificat
CAUTION:
9. Lower vehicle.
10. Pump brake pedal several times to position brake pads and linings. Refill brake master cylinder reservoir with Hig
Brake Pad: Service and RepairRear
REMOVAL
1. Remove brake master cylinder cap and check fluid level in brake master cylinder reservoir. Remove brake fluid u
reservoir is half full. Discard removed fluid.
2. Raise vehicle on hoist.3. Remove wheel and tire assembly.4. Remove rear disc brake caliper bolts.5. Lift rear disc
CAUTION: Do not pry directly against rear disc brake piston and adjuster or damage to piston will occur.
7. Inspect both rear disc brake rotor braking surfaces. Minor scoring or buildup of lining material does not require m
disc brake rotor.
8. Suspend rear disc brake caliper with wire. Use care not to damage rear disc brake caliper or stretch rear brake hose
INSTALLATION
Retracting Caliper
1. Use a 4-inch C-clamp and wood block 70 mm x 25 mm (2-3/4-inch x 1-inch) and approximately 19 mm (3/4 inch)
piston in its bore. This provides necessary clearance for rear disc brake caliper assembly to fit over rear disc brak

CAUTION:
Extra care must be taken during this procedure to prevent damage to caliper piston. Metal or sharp objects canno
2. Remove all rust buildup from inside of outer pad contact area.3. Install inner rear brake pad and lining in caliper p
or distortion and rattles can occur.
4. Install correct outer rear brake pad and lining. Make sure clips are properly seated.5. Install rear disc brake caliper
CAUTION:
7. Top off brake fluid with High Performance DOT-3 Motor Vehicle Brake Fluid C6AZ-19542-AB or DOT-3 equiva
ESA-M6C25-A.
> Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment
98-5A-5Technical Service Bulletin #
Hub-Mount Brake Rotor Machining Equipment
Article No.98-5A-5
03/18/98
^
BRAKES - AVAILABILITY OF HUB-MOUNT BRAKEROTOR MACHINING EQUIPMENT
BRAKE ROTOR MACHINING - AVAILABILITY OFHUB-MOUNT BRAKE ROTOR MACHININGEQUIPME
LINCOLN-MERCURY:1993-94 TOPAZ1993-97 COUGAR1993-98 CONTINENTAL, GRAND MARQUIS, MARK
LIGHT TRUCK:1993-96 BRONCO1993-97 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1993-98 ECONOLINE
^ Steering wheel vibration/nibble
^ vibration
^ Brake pedal pulsation
Brake roughness is caused by:
^
Uneven rotor wear known as Disc ThicknessVariation (DTV). DTV is caused by excessiveLateral Run-Out (LRO)
^ Non-uniform lining transfer
ISSUE:Hub-mount brake rotor machining equipment from Rotunda is now approved for warranty and service use. Brak
ACTION:Use Rotunda Hub-Mount Lathe / Pro-Cut (201-00002) to service vehicles with brake roughness. The hub-mo
^ Improved rotor LRO and "dishing" tolerances
^ Ability to machine rear rotors on live axles, except for trucks with dual rear wheels
^ Easier set-up
> Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining
Equipment > Page 5628

Refer to the Service Procedure for details.
F6AZ-9L494-AA
High Temperature Nickel Anti-SeizeLubricant
SUPERSEDES: 98-4-5
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/balljoints
^ 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
6. Measure rotor thickness and record measurement. Replace rotor if below the minimum thickness specification ca
CAUTION:
DO NOT USE ABRASIVE SANDING DISC SINCE IT WILL REMOVE METAL FROM MOUNTING SURFAC
7. Remove corrosion from wheel mounting surface, both rotor mounting surfaces, and hub mounting surface. A die
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 BEFOR
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.

NOTE:
DEPTH OF CUT SHOULD BE BETWEEN 0.10 AND O.2O mm (0.004 AND 0.008"). LIGHTER CUTS WILL C
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 prev
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 TORQU
14. Install wheels using impact guns equipped with Rotunda AccuTorq(R) sockets. Use a torque wrench on locking l
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:

^ 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

^ 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

> Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 5632
Brake Rotor/Disc: Specifications
Front Diameter 12.44 in
Thickness Nominal 1.1 in
Minimum 1.01 in
Variation, Max 0.00035 in
Runout On Vehicle 0.002 in
Hub Face 0.001 in
Rear Diameter 11.2 in
Thickness Nominal 0.55 in
Minimum 0.51 in
Variation, Max 0.0004 in
Runout On Vehicle 0.002 in
Hub Face 0.001 in
Axle Hub Face 0.002 in
Finish 10-80 micro-in

> Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Description and Operation > Brake Rotor/Disc
Brake Rotor/Disc: Description and OperationBrake Rotor/Disc
Front
Thevented, full-cast
front disc brake with
rotornon-directional
is:- cooling fins.
- mounted on the wheel hub.
- serviced with the disc brake caliper / front disc brake caliper anchor plate assembly removed.
Rear
The rear disc brake rotors are solid full cast drum-in-hat type. The rear disc brake rotor is mounted on the axle flange
> Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Description and Operation > Brake Rotor/Disc > Page 5635
Brake Rotor/Disc: Description and OperationDisc Backing Plate
Thepainted steel
front disc retained
brake rotortoshields
the front wheel spindle with three pop rivets.
are:-
- not interchangeable between sides.
> Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Brake Rotor/Disc: Initial Inspection and Diagnostic Overview
Remove protective coating from new front disc brake rotor with Metal Brake Parts Cleaner (Non-Chlorinated) F5AZ
Brake pulsation (brake roughness) that is present during brake application is caused by rust, foreign material buildup
> Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5638
Brake Rotor/Disc: Component Tests and General Diagnostics
Parallelism
Measuring Thickness Of Disc Brake Rotor Braking Surface
1. With a suitable micrometer, measure the overall thickness of the disc brake rotor braking surface at four or more e
disc brake rotor.
2. Using the lowest reading from Step 1, subtract that number from the other measurements of the disc brake rotor. T
0.010mm (0.0004 inch)
the total amount of thickness variation, or rotor parallelism. A parallelism reading of more than requires disc bra
Runout
CAUTION:
The rotor runout specification must be met to assure proper brake performance without premature vehicle return wi
115 - 142 Nm (85 - 104 ft. lbs.)
1. Do not remove wheel and tire. Tighten lug nuts to . Raise vehicle on hoist.2. Assemble Rotunda Tire and Wheel R
5 mm (0.196 inch)4. Position Rotunda Tire and Wheel Run-Out Gauge Set 134-00199 or equivalent so dial indicato
of rotor. Clamp Rotunda Tire and Wheel Run-Out Gauge Set 134-00199 or equivalent on vehicle making sure fle
5. Do not or
apply
axleany lateral force on rotating
wheel while rotating. Record total indicated runout. Rotate wheel for six revoluti
cover shaft center while wheel.
> Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview >
Page 5639

7. If the runout is not within specification, remove the wheel and tire assembly. Remove rotor and measure the hub f
the stud circle.
8. If the runout of the front hub flange exceeds specification, clean the hub face or install a new hub and bearing asse
runout measurement. Reinstall the rotor and repeat the runout measurement.
less than 0.06 mm (0.002 inch).9. Rotor runout must be If the runout of the hub flange is within specification, reind
wheel and repeat the measurement.
10. If the on-car-mounted hub and rotor still exceeds the specification, replace the rotor, repeat the runout measureme
hub to minimize runout if necessary.
11. Prior to reinstalling the rotor, clean the hub face and backside of rotor hat section of contaminants. Apply High Te
Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A. Install rotor.
12. Reinstall the caliper and caliper bracket.
> Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc
Brake Rotor/Disc: Service and RepairBrake Rotor/Disc
Front
REMOVAL
CAUTION: Use care to avoid damage to the front disc brake rotor and nicking, scratching, or contamination of
2. Remove the wheel and tire assembly from the wheel hub. Be careful to avoid damage to or interference with the b
rotor shield.
3. Remove two caliper anchor plate bolts and discard.4. Remove the front disc brake caliper / front disc brake caliper
out of the way, and support it with a wire to avoid damaging the disc brake caliper or stretching the front brake h
6. Mark the front disc brake rotor and lug bolt position to aid assembly.7. Punch out the mandrels from the rotor-to-h
8. Using a 9.5-mm (3/8-inch) drill, remove the heads from the rotor-to-hub rivets.
CAUTION: Use care to avoid rotor damage while drilling.
9. Remove the front disc brake rotor from the wheel hub.
CAUTION: (TIR) If excessive force is used to remove the front disc brake rotor, the rotor Total Indicated Runo
NOTE:
If the front disc brake rotor does not come off easily, apply Rust Penetrant and Inhibitor F2AZ-19A501-A or eq
10. If necessary, remove any remaining chips or rivet sleeves.
INSTALLATION
1. Clean the hub mounting surface of the front disc brake rotor as well as the hub mounting surface for rust, scale or
allow front disc brake rotor to sit flat to the hub surface.If the front disc brake rotor is being replaced, remove the
NOTE: Rotor machining is not necessary for minor scoring or lining material buildup.
170 - 230 Nm (125 - 169 ft. lbs.)2. Align the painted match marks and position the front disc brake rotor assembly o
115 - 142 Nm (85 - 104 ft. lbs.)
(TIR)wrench to tighten lug nuts to .Check rotor Total Indicated Runout .
CAUTION:
7. Lower vehicle.8. Pump brake pedal several times to position brake pads and linings.9. Road test vehicle.
Rear
REMOVAL
1. Raise vehicle on hoist.2. Remove wheel and tire assembly. Remove rear disc brake caliper assembly. See: Brake P
- If rear disc brake caliper does not require servicing, it is not necessary to disconnect rear brake hose or remov
> Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc > Page 5642

vehicle. Position rear disc brake caliper out of the way and support it with a length of wire to avoid damaging
CAUTION:
Handle rear disc brake rotor and rear disc brake caliper assembly in such a way as to prevent deformation of rot
3. Remove rear disc brake rotor retaining pushnuts and rear disc brake rotor.
CAUTION:
If excessive force must be used during removal of rear disc brake rotor, the rear disc brake rotor should be check
NOTE:
If additional force is required to remove rotor, apply Rust Penetrant and Inhibitor F2AZ-19A501-A or equivalen
INSTALLATION
1. If rear disc brake rotor is being replaced, remove protective coating from new rear disc brake rotor with Carbureto
D8AZ-19579-AA or equivalent meeting Ford specification ESR-M14P9-A. If original rear disc brake rotor is bei
2. Install rear disc brake rotor. Pushnuts do not need to be replaced.3. Install rear disc brake caliper. See: Brake Pad/S
CAUTION:
5. Lower vehicle. Pump brake pedal prior to moving vehicle to position rear brake pads and linings.6. Road test vehi
Refinishing
All disc brake rotor refinishing must adhere to the rule that equal amounts of disc brake rotor stock are removed from
Measuring Thickness Of Disc Brake Rotor Braking Surface
1. With a suitable micrometer, measure the overall thickness of the disc brake rotor braking surface at four equally-sp
brake rotor.
2. Using the lowest reading from Step 1, subtract the minimum allowable thickness stamped into the disc brake rotor
represents the total amount of material available for machining. A thickness reading less than the minimum rear d
3. Remove disc brake caliper / rear disc brake caliper. Position out of the way. Use S-hooks provided with Rotunda O
168-00004 or equivalent.
4. Machine the disc brake rotor. Follow manufacturer's instructions.
Service Limits
CAUTION: Never refinish a disc brake rotor to the minimum wear or discard thickness.
Measure the thickness of the disc brake rotor to determine if it is within the specification. Disc brake rotor minimum

dimension.
Brake Rotor/Disc: Service and RepairDisc Backing Plate

REMOVAL
1. Raise vehicle on hoist.2. Remove front disc brake rotor. It is not necessary to disconnect hydraulic connections.3.
NOTE:
Remove rivets by punching out mandrel located in center of rivet. With a chisel, cut off rivet at front wheel spin
INSTALLATION
1. Locate front disc brake rotor shield until shield attachment surfaces contact front wheel spindle mounting bosses a
with mounting holes in front disc brake rotor shield.
2. Install new rivets using Heavy Duty Riveter 501-D011 or equivalent (three per front disc brake rotor shield) throu
and front wheel spindle. The rivet body head should clamp front disc brake rotor shield securely to spindle bosse
3. Install front disc brake rotor. See: Brake Rotor/Disc/Front4. Make certain front disc brake rotor shield does not co
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service Precautions
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure
Repeat
bleeder comes out.
screw.-
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 5651
NOTE:
of a turn.
CAUTION:
(NGS)
trouble codes.
- Select ABS Module
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Front
Brake Caliper: SpecificationsFront
Caliper Locating Pin Retainer (tighten bottom pin first)............................................................................................

> Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Front > Page 5659
Brake Caliper: SpecificationsRear
Caliper Bleeder Screw ................................................................................................................................................

> Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Page 5660
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Description and Operation > Brake Caliper
Brake Caliper: Description and OperationBrake Caliper
Front
Theare pin
disc slider-type
brake with phenolic caliper pistons, piston seals and press-in type dust boots.
calipers:-
- are mounted to a front disc brake caliper anchor plate which in turn mounts to the front wheel spindle.
- slide-on lubricated disc brake caliper locating pins that are sealed for life from the elements by rubber boots.
Rear
Thesteel
rear rear
disc disc
brakebrake piston.
caliper assembly consists of:-
- rubber O-ring seal positioned in a groove in the rear disc brake caliper housing.
- press-in type dust boot.
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Description and Operation > Brake Caliper > Page 5663

RearRear
discdisc brake
brake caliper
caliper is attachedastofollows:-
is assembled the rear wheel disc brake adapter by two hex head disc brake caliper bolts.
- Rubber insulators isolate the disc brake caliper locating pins from the rear disc brake caliper.
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Description and Operation > Brake Caliper > Page 5664
Brake Caliper: Description and OperationBrake Caliper Bracket
Thetransmits braking
rear wheel torque
disc brake from the inner and outer rear brake pads and linings to the rear axle housing.
adapter:-
- provides a mounting for the parking brake assembly.
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Testing and Inspection > Front
Brake Caliper: Testing and InspectionFront

1. Clean all metal parts with isopropyl alcohol. Then, clean out and dry the grooves and passageways with compresse
brake caliper bore and component parts are thoroughly clean.
2. Check cylinder bore and caliper pistons for damage or excessive wear. Replace a caliper piston if it is pitted, score
worn off.
3. Visually check disc brake caliper. If caliper housing is leaking, it should be replaced. If a seal is leaking, disc brak
and new seals and dust boots installed. If caliper piston is seized in the bore, a new disc brake caliper is required.
4. Inspect locating pin boots in front disc brake caliper anchor plate to make sure they are sealed in groove. Replace
boots that are not properly sealed may cause disc brake caliper locating pin to corrode and brakes to drag.
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Testing and Inspection > Front > Page 5667
Brake Caliper: Testing and InspectionRear
Clean all metal parts with isopropyl alcohol. Then clean out and dry grooves and passageways with compressed air. M
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front
Brake Caliper: Service and RepairFront

DISASSEMBLY
1. Remove disc brake caliper.2. Apply air pressure to the fluid port of disc brake caliper to remove caliper pistons us
CAUTION:
Use a wooden block or layers of shop towels to cushion possible impact of the wheel caliper pistons against the
3. Remove and discard the dust boots from the front disc brake caliper assembly.4. Remove and discard the rubber p
ASSEMBLY
1. Clean and inspect
- Remove the debris.
dirt and caliper pistons and the disc brake caliper.
- Examine the caliper pistons for surface irregularities, scoring or wear. Replace damaged caliper pistons.
- Clean the caliper bores with Metal Parts Brake Cleaner F5AZ-2C410-AA or equivalent meeting Ford specific
- If the caliper bores are corroded or excessively scored, replace the disc brake caliper.
- Lubricate the caliper pistons and piston seals before assembly.
CAUTION: Do not hone the caliper bores. Caliper pistons are not available for honed caliper bores.
2. Install new piston seal and dust boot.
3. Start caliper pistons into caliper bores by hand to assure correct alignment.
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5670

CAUTION: Make sure wheel caliper pistons are not cocked.
4. Install new bleeder screw and bleeder screw cap.5. Make sure dust boot is tight in boot groove on wheel caliper pi
Brake Caliper: Service and RepairRear

DISASSEMBLY
1. Remove rear disc brake caliper assembly. Remove outer rear brake pad and lining by slipping down caliper leg un
inner rear brake pad and lining by pulling it straight out of piston.
2. Apply air pressure to the fluid port in the rear disc brake caliper with Rubber-Tipped Air Gun 100-D009 or equiva
piston. If the rear disc brake piston is seized and cannot be forced from rear disc brake caliper, rear disc brake cal
CAUTION:
Do not use a screwdriver or any similar tool to pry rear disc brake piston out of bore. It will result in damage to
ASSEMBLY
1. When assembling rear disc brake caliper, examine rear disc brake piston for surface irregularities. Replace caliper
clean foreign material from piston surfaces and lubricate with brake fluid before inserting into rear disc brake cal
Retracting Caliper
2. When installing caliper piston back into bore, use a wood block or another flat stock, like an old rear brake pad an
C-clamp and caliper piston.
CAUTION: Do not apply C-clamp directly to piston surface. This can result in damage to caliper piston. Be sur
3. Make sure dust boot is tight in boot groove on caliper piston and in rear disc brake caliper.4. To install inner rear b
piston. Push firmly until pad clip snaps into piston. Do not allow pad or clip tangs to cock during installation.
5. Install rear disc brake caliper.
Brake Caliper: Service and RepairRemoval and Installation
Front
REMOVAL
1. Raise vehicle on hoist.2. Remove the wheel and tire assembly. Use care to avoid damage to, or interference with, t
4. Remove flow bolt that connects hose to disc brake caliper. Remove hose from caliper and plug hose.5. Remove tw
worn or damaged parts.
INSTALLATION
1. Use a 10 cm (4-inch) C-clamp and wood block or used brake pad to seat the caliper pistons in the bores. This mus
for the disc brake caliper to fit over the brake pads during installation.
2. Install replacement disc brake caliper or correct disc brake caliper as marked during removal, with the brake pads
disc brake caliper over front disc brake rotor.
3. Install two new caliper bolts.
Inspect disc brake caliper locating pin and locating pin boots.
NOTE:
It is important to use correct length bolts.
-- Install lower bolt first.
4. Remove plug and install front brake hose on disc brake caliper with new sealing washers on each side of the fitting
40 - 60 Nm (30 - 44 ft. lbs.)and washers. Tighten to .
5. Bleed serviced caliper.6. Install wheel and tire assembly, using Rotunda Accutorq - Lug Nut Sockets 164-R0303 o
CAUTION:
7. Lower vehicle.8. Pump brake pedal several times to position brake pads and linings. Refill brake master cylinder r
Caliper

REMOVAL
1. Raise vehicle on hoist.2. Remove wheel and tire assembly.3. Disconnect flexible rear brake hose from rear disc br
caliper fitting.
4. Remove disc brake caliper bolts.5. Lift rear disc brake caliper off rear wheel disc brake adapter using a rotating m
INSTALLATION
Retracting Caliper
1. Retract caliper piston fully in piston bore and position rear disc brake caliper assembly above rear disc brake rotor
on upper adapter support arm. Install rear disc brake caliper over rear disc brake rotor with rotating motion. Make
CAUTION: Do not pry directly against caliper piston or damage to caliper piston will occur.
2. Install disc brake caliper bolts. Clean inner surface of caliper bushings and lubricate disc brake caliper bolts with S
and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A.
CAUTION: The disc brake caliper bolts must be inserted and started by hand.
22 - 27 Nm (17 - 20 ft. lbs.)

3. Tighten disc brake caliper bolts to .4. Remove plug and install rear brake hose on rear disc brake caliper with new
40 - 54 Nm (30 - 39 ft. lbs.)washers and fittings. Tighten bolts to .

5. Bleed serviced caliper. Always replace rubber rear disc brake bleeder screw cap after bleeding.6. Fill brake master
CAUTION:
Support Bracket
REMOVAL
1. Raise vehicle on hoist.2. Remove rear disc brake rotor and rear disc brake caliper. 3. Remove axle shaft.4. Remov
INSTALLATION
61 - 75 Nm (45 - 55 ft. lbs.)
1. Position rear wheel disc brake adapter on rear axle housing.2. Install four caliper anchor plate mounting bolts and
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications
Brake Fluid: Specifications
High Performance DOT3 Brake FluidFord Specification ESA-M6C25-A

> Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Testing and Inspection > Fluid Color
Brake Fluid: Testing and InspectionFluid Color
NOTE:
Brake fluid contaminated with a hydrocarbon / mineral based fluid (power steering or transmission fluid) can be de
TheFluid
colordiscoloration
of the fluid incan occur due
a normal to system
brake heat andin/ service
or aging.
can vary from its original color for many reasons. Sometim
-
Difference in fluid color of a two-compartment brake master cylinder reservoir can be due to the different operati
- Fluid discoloration can exist when different brands / shades of brake fluid are used in topping off during normal s
-
Fluid discoloration can occur through dissolution of color dye used on brake master cylinder internal springs in m
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Testing and Inspection > Fluid Color > Page 5680
Brake Fluid: Testing and InspectionFluid Level
Always check the fluid level in the master cylinder before performing the test procedures. If the fluid level is not to 4
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Brake Hose
Brake Hose/Line: SpecificationsBrake Hose

To Caliper
Front .................................................................................................................................................................................
NOTE: All hydraulic lines must be tightened to the specific torque value and be free of leakage.
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Brake Hose > Page 5685
Brake Hose/Line: SpecificationsBrake Line

3/8 x 24, All Connections ....................................................................................................................................................
NOTE: All hydraulic lines must be tightened to specific torque values and be free of leakage.
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 5686
Brake Hose/Line: Testing and Inspection
Inspect the brake tubes under the vehicle for damage and proper routing. Ensure that the brake lines are routed away
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Front
Brake Hose/Line: Service and RepairFront

REMOVAL
1. Raise vehicle on hoist.2. Remove the wheel and tire assembly from the wheel hub. Use care to avoid damage to, o
during removal.
3. Disconnect the flexible front brake hose from the disc brake caliper as follows:
a. Loosen the tube fitting that connects the front brake hose to the brake tube at the bracket on the frame.b. Plug t
correctly during installation.
INSTALLATION
40 -1. Install the flexible front brake hose to the disc brake caliper with hollow bolt and two new sealing washers. Ti
60 Nm (30 - 45 ft. lbs.).
2. Install the screw retaining the bracket to frame. Remove the plug from the brake tube. Connect the brake tube to th
14 - 20 Nm (10 - 14 ft. lbs.)fitting nut. Tighten to .
NOTE: Do not twist the front brake hose.
3. Bleed the component serviced and centralize the brake pressure differential valve.4. Fill the brake master cylinder
equivalent fluid meeting Ford specification ESA-M6C25-A.
115 - 142 Nm (85 - 104 ft. lbs.)
5. Install the wheel and tire assembly. Tighten lug nuts to .6. Lower vehicle.
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Front > Page 5689
Brake Hose/Line: Service and RepairRear

REMOVAL
1. Raise vehicle on hoist.2. Remove wheel and tire assembly.3. Disconnect flexible brake hose from rear disc brake c
fitting.
INSTALLATION
1. Remove plug and install rear wheel brake hose on rear disc brake caliper with new gasket on each side of fitting o
40 - 60 Nm (30 - 45 ft. lbs.)through washers and fittings. Tighten bolts to .
115 - 142 Nm (85 - 104 ft. lbs.)

2. Bleed the component serviced. Always replace rubber rear disc brake bleeder screw cap after bleeding.3. Fill brak
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications
Brake Proportioning/Combination Valve: Specifications

CONTROL VALVE SPECIFICATIONS
Pressure Differential .........................................................................................................................................................
Pressure Control Valve-to-Master Cylinder .....................................................................................................................
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 5693
Brake Proportioning/Combination Valve: Description and Operation
Theregulates the hydraulic

brake pressure control pressure
valve:- in the rear brake system.
Operation is as follows:-
When the brake pedal is applied, the full, rear brake fluid pressure passes through the proportioning valve to the r
-
Above its split point, the proportioning valve begins to reduce the hydraulic pressure to the rear brakes, creating a
> Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications
Hydraulic Control Assembly - Antilock Brakes: Specifications
Retaining Nuts .....................................................................................................................................................................

> Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 5697
EVAC And Fill Connector

Hydraulic Control Assembly - Antilock Brakes: Description and Operation
TheBrake
HCU pressure control
consists of valve block.
the following components:-
- Pump motor.
Duringof
Operation normal braking,
the HCU is as fluid passes through four normally open inlet valves, one to each wheel.
follows:-
-
If the anti-lock brake control module senses a wheel is about to lock, it pulses the appropriate inlet valve which c
-
The anti-lock brake control module then looks at that wheel again. If it is still decelerating, it opens the closed ou
-
The traction control portion of the brake pressure control valve block contains two isolation valves for traction co
The brake pressure control valve block and pump motor are replaced as an assembly.
Hydraulic Control Assembly - Antilock Brakes: Service and Repair

REMOVAL
(ACL)
1. Disconnect battery ground cable.2. Remove engine Air Cleaner and air cleaner outlet tube.3. Disconnect 25-pin c
4. Remove the two inlet brake tubes and the three anti-lock outlet brake tubes, or the four anti-lock traction control b
control module. Plug each port to prevent brake fluid from spilling on paint and wiring.
5. Remove the three 13 mm bolts retaining the hydraulic control unit to the mounting bracket. Remove hydraulic con
INSTALLATION
16 - 24 Nm (12 - 17 ft. lbs.)
1. Make sure hydraulic control unit is fully seated in bracket. Install the three retaining bolts. Tighten to .2. Connect
14 - 24 Nm (11 - 17 ft. lbs.)control module and two tubes to inlet ports on top of the hydraulic control module. T
3. Connect 25-pin connector to anti-lock brake control module.4. Install engine air cleaner and air cleaner outlet tube
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications
Brake Master Cylinder: Specifications
Master Cylinder To Booster .................................................................................................................................................

> Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Locations > Master Cylinder Push Rod
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Locations > Master Cylinder Push Rod > Page 5705
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Locations > Page 5706
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Locations > Page 5707
Brake Master Cylinder: Service Precautions

CAUTION:
front brake
Blistering caliper seals
or swelling indicates contamination of brake fluid by a petroleum-based solvent or oil. In that case, all ru
- front brake hoses
- rear wheel brake hoses
- master cylinder cap gasket
- brake pressure control valves
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Brake Fluid Reservoir
Brake Master Cylinder: Description and OperationBrake Fluid Reservoir
Theisbrake
mounted to the
master brakereservoir:-
cylinder master cylinder.
- holds fluid supply for each brake master cylinder hydraulic piston.
- provides visual fluid level markings.
- contains the brake master cylinder fluid level switch.
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Brake Fluid Reservoir > Page 5710
Brake Master Cylinder: Description and OperationMaster Cylinder Push Rod
The power brake booster has an adjustable push rod (output rod) which is used to compensate for dimensional variat
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Brake Fluid Reservoir > Page 5711
Brake Master Cylinder: Description and OperationMaster Cylinder, Brakes
Description
WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONT
Thebrake
brakemaster
mastercylinder
cylinder has common plastic brake master cylinder reservoir and fluid level indicator combined in
- brake pressure control valve
- brake tubes and hoses
Operation
TheWhen
brake the brake
master pedal isisapplied,
cylinder pressure
a dual-piston is applied
type. by master
The brake mechanical linkage
cylinder to theasprimary
operates and secondary pistons.
follows:-
- Brake master cylinder pistons apply hydraulic pressure to the two opposed hydraulic circuits.
Thebrake
brakemaster
mastercylinder
cylinderreservoir
consists of:-
- primary and secondary pistons
- brake master cylinder body
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Brake Master Cylinder: Initial Inspection and Diagnostic Overview
Abnormal Conditions
NOTE: Prior to performing any diagnosis, make sure the brake system warning indicator is functional.
Brakeinpedal
Changes brakegoes down
pedal feelfast. This are
or travel could be caused
indicators by an external
something or internal
could be wrong inleak.
the brake system. The diagnosis pro
- Brake pedal eases down slowly. This could be caused by an external or internal leak.
-
Brake pedal is low or feels spongy. This condition may be caused by no fluid in the brake master cylinder reservo
- Brake pedal effort is excessive. This may be caused by a bind or obstruction in brake pedal linkage or insufficien
-
Rear brakes lock up during light brake pedal force. This may be caused by wrong tire pressure, worn tires, grease
-
Brake pedal effort is erratic. This condition could be caused by power brake booster malfunction, extreme caliper
-
Brake warning indicator is on. This may be caused by low fluid level, ignition wire routing too close to fluid leve
Normal Conditions
Usually the first and strongest indicator of anything wrong in the brake system is a feeling through the brake pedal.T
A slight turbulence in the brake master cylinder reservoir fluid occurring when the brake pedal is released. Turbu
-
A trace of brake fluid exists on booster shell below the brake master cylinder mounting flange. This condition res
- Fluid level will drop with lining wear.
Cleaning
1. Wash brake master cylinder body, especially bore, along with primary piston and secondary piston assemblies in c
isopropyl alcohol can also be used.
2. Inspect seals on primary and secondary piston assemblies for cuts, nicks, scratches or signs of wear and for presen
NOTE:
The aluminum body of the brake master cylinder is anodized. Some signs of bore wear on the anodized surface,
3. Inspect brake master cylinder bore for pitting, corrosion or heavy wear. Heavy wear is characterized by scoring or
CAUTION: Honing of the bore on aluminum brake master cylinders is not permitted as the anodic coating and
4. Replace if necessary.
Inspection
14 - 20 Nm (10 - 14 ft. lbs.)
When in the brake master cylinder area, check the brake tubes and brake master cylinder mounting. The brake tubes
Low fluid level detected without signs of leakage; this condition is caused by displacement of fluid from the brak
-
A momentary or slight squirt of brake fluid within the brake master cylinder reservoir upon application of the bra
-
- Slight turbulence in the brake master cylinder fluid when the brake pedal is released; turbulence occurs as brake f
A trace of brake fluid found on the outside of the power brake booster below the brake master cylinder mounting
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page
Brake Master Cylinder: Component Tests and General Diagnostics
Bypass Conditions Test
1. Check fluid in brake master cylinder. Fill brake master cylinder reservoir if low or empty.2. Observe fluid level in
torque required to rotate wheels with brakes applied as follows:
- Place transmission in NEUTRAL and raise vehicle on hoist.
-
Apply brakes slowly to a minimum of 445 N (100 lbs.) and hold for approximately 15 seconds. With brakes still
Fluid Level Check
Brake fluid level in the brake master cylinder reservoir should be between 4 mm (0.16 inch) below the MAX line on
Master Cylinder Push Rod
A push
A power rod which
brake boosteristhat
too is
long will prevent
suspected the brake
of having master cylinder
an improper push rodpiston
lengthfrom
will completely releasing
indicate either hydraulic p
of the following:-
- A push rod which is too short will increase brake pedal travel causing a clunking or groaning noise from the pow
Non-Pressure Leaks
An empty brake master cylinder reservoir condition may be caused by two types of non-pressure external leaks.-
An external leak may occur at the brake master cylinder reservoir cap because of improper positioning of the gas
- An external leak may occur at the brake master cylinder reservoir mounting grommets. Service such a leak by ins
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Page 5715
Brake Master Cylinder: Adjustments
If necessary, a booster push rod length can be verified with a push rod gauge using the following procedure:1. Witho
cylinder must be supported to prevent damaging the brake tubes.
2. With the engine idling, gauge and adjust the push rod length. A force of approximately 22 N (5 lbs.) applied to the
make sure that the push rod is seated with the power brake booster.
213. After push rod adjustment, install the brake master cylinder on the power brake booster. Gradually alternate the
- 29 Nm (16 - 21 ft. lbs.)
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir
Brake Master Cylinder: Service and RepairBrake Fluid Reservoir

REMOVAL
NOTE: Whenever the brake master cylinder reservoir is removed from the brake master cylinder, new grommets mus
1. Disconnect brake fluid level warning switch.2. Remove brake master cylinder filler cap from brake master cylinde
front locating pin and rock the brake master cylinder reservoir up and away from the rear locating pin.
4. Remove secondary brake master cylinder port in same manner and discard complete brake master cylinder reservo
INSTALLATION
1. Coat grommets with clean brake fluid and press into brake master cylinder.2. Coat brake master cylinder reservoir
reservoir retaining legs on pins while pressing reservoir ports into grommets.
3. Connect fluid level indicator switch.4. Fill brake master cylinder reservoir with specified brake fluid to between M
Performance DOT-3 Motor Vehicle Brake Fluid C6AZ-19542-AB or DOT-3 equivalent fluid meeting Ford speci
5. Check for leaks.
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 5718
Brake Master Cylinder: Service and RepairMaster Cylinder, Brakes
Overhaul
CAUTION:
On vehicles equipped with ABS and traction control, the brake master cylinder must NOT be overhauled, because of
On vehicles with ABS without traction control or without ABS, the brake master cylinder is serviced as follows:
DISASSEMBLY
NOTE:
If brake master cylinder is to be put into a vise to aid in disassembly, mount into vise by flange only to avoid damag
1. Clean the outside of the brake master cylinder thoroughly. Remove the brake master cylinder filler cap and gasket
.
2. Remove stop bolt and pressure control valve by unscrewing from brake master cylinder. The brake master cylinde
unless the stop bolt and pressure control valve are removed.

Piston Snap Ring
3. Depress the primary piston and remove snap ring from retaining groove at the open end of the bore.4. Remove the
remove pistons. If secondary piston does not readily come out, apply air pressure to secondary outlet port to assis
ASSEMBLY
1. Dip replacement piston assemblies in High Performance DOT-3 Motor Vehicle Brake Fluid C6AZ-19542-AB or D
specification ESA-M6C25-A for lubrication prior to assembly into brake master cylinder. Attempting to assembl
13 - 24 Nm (10 - 17 ft. lbs.) 1 - 4 Nm (9 - 352. Install secondary (smaller) piston assembly into bore, spring end first
inch lbs.).
6. Fill and bleed brake master cylinder with specified brake fluid. See: Brake Bleeding/Service and Repair/Master Cy
Removal and Installation
REMOVAL
1. Press the brake pedal several times to exhaust all vacuum in the system.

2. Remove brake tubes from primary and secondary outlet ports of brake master cylinder.
INSTALLATION
21 - 29 Nm (16 - 21 ft. lbs.)

14 - 20 Nm (10 - 14 ft. lbs.)
1. Position brake master cylinder as an assembly on studs on booster assembly.2. Install retaining nuts. Tighten retain
reservoir. Use High Performance DOT-3 Motor Vehicle Brake Fluid C6AZ-19542-AB or DOT-3 equivalent fluid
6. Bleed brake system.7. Operate brakes several times, then check for external hydraulic leaks.
3. Disconnect the brake warning indicator switch connector.4. Remove two nuts retaining brake master cylinder to p
> Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Page 5721
Brake Master Cylinder: Tools and Equipment
Booster Push Rod Gauge
If necessary, a booster push rod length can be verified with a push rod gauge using the dimensions shown.
> Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Specifications
Parking Brake Cable: Specifications

Front Cable and Conduit Retainer ......................................................................................................................................
> Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Specifications > Page 5726
> Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable and Conduit
Parking Brake Cable: Service and RepairFront Cable and Conduit
REMOVAL
1. Raise vehicle on hoist.2. Release parking brake cable tension. See: Adjustments/Tension Adjustment3. Disconnec
remove screw holding plastic inner front fender apron to frame.
5. Pull back front fender apron to expose front parking brake cable and conduit.6. Pull parking brake rear cable and c
panel. Disconnect front parking brake cable and conduit from parking brake control at clevis.
8. Using a 13 mm box-end wrench, press retaining tabs and remove front parking brake cable and conduit from parki
INSTALLATION
1. Start front parking brake cable and conduit through opening in the dash panel inside passenger compartment.2. Co
Install sound deadener cover patch at dash panel.
3. Raise vehicle. Insert front parking brake cable and conduit through frame member toward rear of vehicle. Press tab
hole.
4. Connect front parking brake cable and conduit to parking brake rear cable and conduit connector.5. Adjust parking
> Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable and Conduit > Page 5729
Parking Brake Cable: Service and RepairRear Cable and Conduit

REMOVAL
1. Raise vehicle.2. Release parking brake cable tension. See: Adjustments/Tension Adjustment3. Disconnect front pa
retainer on RH rear axle housing by removing bolt and retainer.
8. Remove cable retaining E-clip and cable eyelet from rear parking brake cable. Pull parking brake rear cable and co
brake adapter boss.
9. Remove parking brake rear cable and conduits from vehicle.
INSTALLATION
1. Insert parking brake rear cable and conduit through mounting boss and connect it to rear parking brake lever.2. Pu
locked into place.
4. Route rear parking brake cable LH under RH cable between stabilizer bar stud and shock absorber. Connect RH ca
(part of parking brake rear cable and conduit LH).
5. Attach tie-strap on RH parking brake rear cable and conduit to rear stabilizer bar.6. Connect parking brake rear cab
> Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications
Parking Brake Control: Specifications

Parking Brake Control-to-Body Bolts .................................................................................................................................
> Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Testing and Inspection > Brakes, Rear
Parking Brake Control: Testing and InspectionBrakes, Rear

Apply the brake pedal a few times and verify the rear brakes do not drag when rear wheels rotate.
> Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Testing and Inspection > Brakes, Rear > Page 5735
Parking Brake Control: Testing and InspectionControl Stroke, Parking Brake

Verify the parking brake control lever stroke is five to seven notches when applied with a pedal effort of 170 N (125
> Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Testing and Inspection > Page 5736
Parking Brake Control: Service and Repair

REMOVAL
1. Disconnect battery ground cable.2. Fully release parking brake.3. Raise vehicle on hoist.4. Release cable tension.
5. Separate front parking brake cable and conduit from parking brake rear cable and conduits at the connector.6. Low
7. Partially remove scuff plate and partially remove front door lower weatherstrip.
8. Remove parking brake release handle mounting screw from instrument panel steering column cover. Slide parking
down to remove from instrument panel steering column cover.
9. Remove center instrument panel mouldings (RH and LH) to gain access to instrument panel steering column cove

(PCM)
10. Remove instrument panel steering column cover retaining bolts and remove instrument panel steering column cov
16. Remove LH lower instrument panel retaining bolts.
NOTE:
Pull and retain the instrument panel rearward slightly by installing a small block of wood or similar tool betwee
17. Remove parking brake control retaining bolts.

18. Lower parking brake control. Disconnect the front parking brake cable and conduit from parking brake control ree
release lever.
INSTALLATION
1. Attach parking brake release handle to parking brake control by snapping two parking brake handle bushings into
lever.
25 - 35 Nm (19 - 25 ft. lbs.)2. Position parking brake control and connect front parking brake cable and conduit.3. In
10 - 14 Nm (89 - 123 inch4. Remove wood block from instrument panel and install lower instrument panel retaining
lbs.).
5. Install powertrain control module.6. Install steering column-to-parking brake control shake brace.7. Attach parking

9. Install LH cowl side trim panel.
10. Install lower instrument panel steering column cover except lower LH screw and install center instrument panel m
12. Position scuff plate and install retaining screws.
13. Attach parking brake release handle to instrument panel steering column cover by inserting handle locator tab thro
1 - 2 Nm (9 - 17 inch lbs.)sliding the parking brake release handle forward. Install parking brake release handle m
NOTE:
If the release handle locator tab is not fed through the column cover locating hole, the parking brake release han

14. Raise vehicle. Connect front parking brake cable and conduit to parking brake rear cable and conduit.15. Adjust p
> Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications
Parking Brake Lever: Specifications

Release Handle Mounting Screw..........................................................................................................................................
> Brakes and Traction Control > Parking Brake System > Parking Brake Release Motor > Component Information > Specifications
Parking Brake Release Motor: Specifications

Retaining Screw ...................................................................................................................................................................
> Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Locations
> Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Locations > Page 5750
Theisautomatic
a vacuumparking
Pinpoint Test G1
REMOVAL
INSTALLATION
2-3 Nm (18-26 inch lbs.).
> Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair
Parking Brake Shoe: Service and Repair

REMOVAL
1. Remove axle shaft assembly.2. Disconnect parking brake rear cable and conduit from rear parking brake cable.3. R
assembly.
6. Remove upper brake shoe adjusting screw spring.
7. Lift parking brake shoe and linings over support and remove parking brake shoe and linings and rear parking brak
CAUTION: Make sure rear parking brake cable does not damage boot or pull boot out of position.
8. Disassemble parking brake shoe and linings, parking brake lever and parking brake return springs.
INSTALLATION
1. Install lower parking brake return spring and rear parking brake cable to parking brake shoe and lining assemblies
2. Make sure parking brake lever boot is properly positioned in parking brake support plate. Install parking brake sho
inserting rear parking brake cable through boot, lowering shoes into position.
3. Install upper brake shoe adjusting screw spring.4. Install brake shoe adjustment screw assembly.5. Install brake sh
Parking Brake Shoe And Linings Wear Limit Specifications
8. Center parking brake shoe and linings on parking brake support plate and, using an 8-inch micrometer, gauge park
dimensions shown.
> Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications
Vacuum Brake Booster: Specifications

Power Brake Booster Push Rod Length ........................................................................................................................ 5
Booster to Dash Panel ......................................................................................................................................................

> Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 5760
> Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 5761
Vacuum Brake Booster: Description and Operation
WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONT
Theisdiaphragm-type
self-contained. power brake booster:-
- is mounted on the engine side of the dash panel.
- uses engine intake manifold vacuum and atmospheric pressure for its power.
- must be replaced with a new power brake booster if it becomes damaged or inoperative.
- utilizes a power brake booster check valve to provide temporary power assist when the vacuum source is reduced
The power brake booster check valve and grommet are serviced separately. The hose is serviced as an assembly with
> Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Vacuum Brake Booster: Initial Inspection and Diagnostic Overview
Pedal Reserve Check
When a low brake pedal or the feel of a bottomed-out condition exists, check for brake pedal reserve.1. Operate engi
NOTE: This increased resistance may feel like something has bottomed out.
5. Hold brake pedal in applied position and raise the engine speed to approximately 2,000 rpm.
6. Release accelerator pedal and observe that brake pedal moves downward as engine returns to idle speed.
NOTE:
The additional movement of the brake pedal is the result of the increased engine manifold vacuum which exerts
Visual Inspection
1. Disconnect the vacuum hose.2. Inspect the hose for cuts, abrasions and cracks.
- All unused vacuum connectors should be capped.
- Hoses and their connections should be properly secured in good condition with no holes or no collapsed areas
3. Apply both vacuum and pressure on the engine side of the hose.4. Verify that the air flows only toward the engine
NOTE: An arrow on the hose and power brake booster check valve assembly indicates the correct orientation of
> Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5764
Vacuum Brake Booster: Component Tests and General Diagnostics
1. Check the hydraulic brake system for leaks or insufficient fluid.2. With the transmission in PARK, stop the engine
the vacuum system is operating, the brake pedal will move downward under constant foot pressure. If no motion
4. Remove the vacuum hose from the power brake booster check valve. Manifold vacuum should be available at the
the engine at idle speed and the transmission in NEUTRAL. Make sure all unused vacuum outlets are properly ca
5. Operate the engine a minimum of 10 seconds at fast idle. Stop the engine and let the vehicle stand for 10 minutes.
approximately 89 N (20 lbs.) of force. The pedal feel (brake application) should be the same as that noted with th
> Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 5765
Vacuum Brake Booster: Adjustments
TheAvacuum
push rod that is
power too long
brake willonprevent
booster the brake
non-ABS master
vehicles cylinder
has an piston
adjustable from
push rodcompletely releasing
(output rod) which ishydraulic pres
used to com
- A push rod that is too short will increase brake pedal travel and cause a groaning noise from the power brake boo
If necessary, booster push rod length can be verified with a push rod gauge by using the following procedure:1. With
CAUTION: The brake master cylinder must be supported to prevent damaging the brake tubes.
2. With the engine running, gauge and adjust the push rod length from the knurled area. A force of approximately 22
rod with the gauge will make sure that the push rod is seated within the power brake booster.
CAUTION: Do not adjust push rod length too long or brake drag could result.
21 - 29 Nm (16 - 21 ft. lbs.)3. Install the brake master cylinder on the power brake booster. Gradually alternate tight
> Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 5766
Vacuum Brake Booster: Service and Repair
REMOVAL
tubes, but be careful not to kink brake tubes. Kinking of brake tubes can lead to tube damage.
4. Disconnect manifold vacuum hose from power brake booster check valve.5. Working inside vehicle below dash p
brake pedal pin just far enough for outer plate of stoplight switch to clear pin. Then remove stoplight switch from
6. Remove booster-to-dash panel retaining nuts. Slide booster push rod and brake master cylinder push rod bushing o
INSTALLATION
1. Place power brake booster in position on dash panel.2. Working inside vehicle, position booster push rod and brak
3. Position stoplight
21 - 29 Nm (16 - switch so that
21 ft. lbs.) it panel
dash straddles
withbooster push rod
self-locking with
nuts. switchtoslot
Tighten . toward pedal blade and hole just clea
completely onto pin. Be careful not to bend or deform stoplight switch.
4. Install brake master cylinder push rod spacers on pin and secure all parts to pin with hairpin retainer. Make sure re
locked overbattery
1. Disconnect pedal ground
pin. Install stoplight
cable.2. switch
Exhaust wiringvacuum
residual connector on stoplight
by pressing brakeswitch.
pedal four to five times.3. Remove
21 - 29 Nm (16 - 21 ft. lbs.)

5. Connect manifold vacuum hose to power brake booster check valve using hose clamp.6. Position brake master cyl
> Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Service and Repair
Vacuum Brake Booster Check Valve: Service and Repair

REMOVAL
NOTE: If replacement is necessary, replace the hose and power brake booster check valve as an assembly.
1. Disconnect the check valve vacuum hose from the vacuum outlet manifold.
NOTE: The power brake booster check valve is pressed into the hose. An arrow on the hose indicates the directi
2. Remove power brake booster check valve from power brake booster.
INSTALLATION
1. Install power brake booster check valve into power brake booster.2. Connect check valve vacuum hose to vacuum
> Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer
Module: > 98-19-7 > Sep > 98 > Engine - Hesistation When Accelerating
Article No.98-19-7
09/28/98
ISSUE
ACTION
NOTE
SERVICE PROCEDURE
2.

4.
NOTE
> Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service
Bulletins > Customer Interest for Electronic Brake Control Module: > 98-19-7 > Sep > 98 > Engine - Hesistation When Accelerating > Page 5779

DEALER CODING
CONDITION
BASIC PART NO. CODE
2C219 42
OASIS CODES: 301000, 607000, 607500, 611000, 611500, 614000, 614500

> Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Techn
Brake Control Module: > 98-19-7 > Sep > 98 > Engine - Hesistation When Accelerating
Article No.98-19-7
09/28/98
ISSUE
ACTION
NOTE
SERVICE PROCEDURE
2.

4.
NOTE
> Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 98-19-7 > Sep > 98 > Engine - Hesistation When Accelerating > Page 5785

DEALER CODING
CONDITION
BASIC PART NO. CODE
2C219 42
OASIS CODES: 301000, 607000, 607500, 611000, 611500, 614000, 614500

> Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5786


Engine View

(HCU).
-
- (DTC)

REMOVAL
INSTALLATION

> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Diagrams

> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations
> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Locations > Page 5798
Theisautomatic
a vacuumparking
Pinpoint Test G1
REMOVAL
INSTALLATION
2-3 Nm (18-26 inch lbs.).
> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications

> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 58

> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front
Part 1 Of 2
Part 2 Of 2
> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front > Page 5808
> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 5809
> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring
Front Axle
Rear Axle
REMOVAL
> Page 5812

CAUTION:
INSTALLATION
> Page 5813


> Page 5814

> Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 5815
Front
Part 1 Of 2
Part 2 Of 2
REMOVAL
INSTALLATION
5 - 6 Nm (45 - 53 inch lbs.)
Rear
> Page 5816

REMOVAL
INSTALLATION
5 - 6 Nm (45 - 53 inch lbs.)
> Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks
Article No.99-24-2
11/29/99

> Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service


NOTE

^
^
NOTE

NOTE

NOTE
NOTE

> Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Cylinder Inope

NOTE:
REMOVAL
drill.
INSTALLATION
> Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Cylinder Inope
REMOVAL
INSTALLATION
> Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations
Transmission View

> Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 5835
> Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations

> Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5840


- Pull-in coil
- Contacts


REMOVAL
INSTALLATION
> Starting and Charging > Battery > Component Information > Specifications > Electrical Specifications
Battery: Electrical Specifications
Amps/Hour Rate/Volts
Voltage .................................................................................................................................................................................
Parasitic Draw (Current Drain) Less Than 0.05 amps

For testing procedures, please refer to Battery Drain Test.
> Starting and Charging > Battery > Component Information > Specifications > Electrical Specifications > Page 5847
Battery: Mechanical Specifications
Battery Terminal Bolts/Nuts ................................................................................................................................................

> Starting and Charging > Battery > Component Information > Service Precautions > Environmental Impact Information
Battery: Environmental Impact Information
Ford Motor Company strongly recommends that lead-acid batteries be returned to an authorized recycling facility for d
> Starting and Charging > Battery > Component Information > Service Precautions > Environmental Impact Information > Page 5850
Battery: Technician Safety Information

WARNING
BATTERIES NORMALLY PRODUCE EXPLOSIVE GASES WHICH CAN CAUSE PERSONAL INJUR
-
WHEN LIFTING A PLASTIC-CASED BATTERY, EXCESSIVE PRESSURE ON THE END WALLS CO

-
KEEP OUT OF REACH OF CHILDREN. BATTERIES CONTAIN SULFURIC ACID. AVOID CONTAC
-
THE BACKUP POWER SUPPLY ENERGY MUST BE DEPLETED BEFORE ANY AIR BAG COMPON
> Starting and Charging > Battery > Component Information > Service Precautions > Page 5851
Battery: Description and Operation

12 voltVehicles are equipped with a maintenance-free battery.
> Starting and Charging > Battery > Component Information > Testing and Inspection > Battery Base Voltage Test
Battery: Testing and InspectionBattery Base Voltage Test

NOTE: 10-15 seconds
Prior to running this test, turn the headlamp bulbs on for to remove any surface charge from the battery. Then, wait u
1. With the ignition OFF and no electrical loads on, connect the negative C-) lead of Rotunda 73 Digital Multimeter
battery ground cable clamp.
2. Connect the positive (+) lead of the voltmeter to the battery to starter relay cable clamp.3. Read and record the bat
> Starting and Charging > Battery > Component Information > Testing and Inspection > Battery Base Voltage Test > Page 5854
Battery: Testing and InspectionBattery Capacity Test

(ARBST)
To perform this test use a high rate discharge tester, Rotunda Alternator, Regulator, Battery and Starter Tester 010-007
1. Turn the control knob on ARBST 010-00725 or equivalent to the OFF position.2. Turn the multimeter selector sw
multimeter clips must contact the battery posts and not the ARBST tester clips. Unless this is done, the actual bat
15 seconds4. Turn the load control knob in a clockwise direction until the ammeter reads approximately half of the c
15 secondsperiods longer than .
9.6 volts 21C (70F)
9.6 volts 21C (70F)6. If the multimeter reading is at or more, the battery has a good output capacity and will readily
replaced. If unsure about the battery's state of charge, charge the battery.
9.6 volts 21C (70F)8. After the battery has been charged, repeat the capacity test. If the capacity test battery voltage
9.6 21C (70F)battery. If the voltage is or more at, the battery is satisfactory for service.
9. If the battery is found to be discharged only, check for a loose drive belt, loose electrical connection, charging syst
Drain Testing. See: Drain Test
Battery: Testing and InspectionBattery Load Test
2000 rpm 0.5 volts1. With the engine running, turn the air conditioner on the blower motor on high speed and the he
-
If the voltage does not increase as specified, refer to Generator On-Vehicle Tests and Generator Bench Tests.
- If the voltage increased as specified, the charging system is operating normally. Proceed to the battery drain te
Battery: Testing and InspectionBattery No-Load Test
1500 rpm
14.1 14.7 volts1. Connect Rotunda 88 Digital Multimeter 105-R0053 or equivalent to monitor engine speed.2. Conne
- 2.5 voltsIf the voltage increase is less than over the base voltage, perform the Load Test. See: Battery Load T
- 2.5 volts
If there is no voltage increase or the voltage increase is greater than , perform the Generator On-Vehicle Tests
Battery: Testing and InspectionDrain Test
Drains Which Shut Off W/Battery Cable Disconnected

50 milliamps
Check for current drains on the battery in excess of with all the electrical accessories off and the vehicle at rest. Curren
WARNING: DO NOT ATTEMPT THIS TEST ON A LEAD-ACID BATTERY THAT HAS RECENTLY BEE
CAUTION: 10 A Do not crank the engine or operate accessories that draw more than . You could open the fuse in the
NOTE: 10 mA Many control modules draw or more continuously.
one minute1. Repeat Steps 1 through 6 of the voltmeter drain testing. See: With Ammeter, In-Line Test Procedure2
turn off.
3. Connect the voltmeter and read the voltage.
Test conclusion
0.05 amp 0.05 amp
The current reading (current drain) should be less than . If it exceeds after a few minutes, and if this drain did no
With Ammeter, In-Line Test Procedure
50 milliamps
Check for current drains on the battery in excess of with all the electrical accessories off and the vehicle at rest. Curren
WARNING: DO NOT ATTEMPT THIS TEST ON A LEAD-ACID BATTERY THAT HAS RECENTLY BEE
CAUTION: 10 A Do not crank the engine or operate accessories that draw more than . You could open the fuse in the
NOTE:
- 10 mAMany control modules draw or more continuously.
- Use an in-line ammeter between the battery positive or negative post and its respective cable.

1. Insert the test leads in the input terminals.2. Turn switch to mA/A dc.3. Disconnect battery terminal and touch pro
Test Conclusion
0.05 amps 0.05 amps
The current reading (current drain) should be less than . If it exceeds it indicates a constant current drain which
> Starting and Charging > Battery > Component Information > Service and Repair > Removal and Installation
Battery: Service and RepairRemoval and Installation
Battery
REMOVAL
WARNING: BATTERIES NORMALLY PRODUCE EXPLOSIVE GASES WHICH CAN CAUSE PERSON
NOTE
- (PCM) 18 km (10 miles)When the battery has been disconnected or reconnected, some abnormal drive symptom
-
When the battery has been disconnected or reconnected, volatile memory information will be lost. Systems affect
1. Remove battery cables from battery terminals (battery ground cable first).
2. Remove battery heat shield.3. Remove battery hold down clamp.4. Remove battery from vehicle.
WARNING: WHEN LIFTING A PLASTIC-CASED BATTERY EXCESSIVE PRESSURE ON THE END

INSTALLATION
1. Clean and neutralize cable terminals, battery tray and battery posts.2. Neutralize and clean battery tray with a wire
to specification. Do not over-tighten.
WARNING: WHEN LIFTING A PLASTIC-CASED BATTERY, EXCESSIVE PRESSURE ON THE EN

4. Reinstall battery heat shield.
> Starting and Charging > Battery > Component Information > Service and Repair > Removal and Installation > Page 5861

6-10 Nm (54-88 Lb-In)5. Secure cables (positive first) to proper terminals. Tighten to . Apply a small quantity of Pr
XG-1-C or XG-1-K or equivalent meeting Ford specification ESA-M1C75-B to terminals.
Battery Tray
REMOVAL
1. Remove battery from vehicle.2. Remove retaining bolts, screws and washers from battery tray.3. Remove battery t
INSTALLATION
8-12 Nm (71-106 Lb-In)
8-12 Nm (71-106 Lb-In)1. Position battery tray to front fender apron in engine compartment.2. Install retaining bolt
> Starting and Charging > Battery > Component Information > Service and Repair > Removal and Installation > Page 5862
Battery: Service and RepairCleaning and Inspection
Battery Cleaning
Keep the battery top clean and dry to reduce the need for service and extend battery life. Also, make certain the cable c
Water Addition
24 months 24,000 miles (40,000 km)

The Motorcraft maintenance-free battery normally does not require additional water during its life of service. However
> Starting and Charging > Battery > Component Information > Service and Repair > Page 5863
Battery: Tools and Equipment

TOOLS
Anyone working with a battery needs the proper tools. Using the right tools will prevent damage to the battery, b
Tools and equipment manufactured for servicing batteries have insulated parts to help prevent arcing should the t
Clamp Spreader
The spreader is used to expand the cable clamp after it has been removed from the terminal and the clamp bolt h
Terminal Cleaning Brush
The terminal cleaning brush is designed with units to clean both the tapered battery terminal and the mating surf
Carrier
Use a suitable battery carrier for lifting and transporting the battery. The illustration shows a clamp-type carrier u
WARNING-
- BATTERIES NORMALLY PRODUCE EXPLOSIVE GASES WHICH CAN CAUSE PERSONAL
WHEN LIFTING A PLASTIC-CASED BATTERY, EXCESSIVE PRESSURE ON THE END WAL

> Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications
Alternator: Electrical Specifications
Rating (gen. crank/rev) ........................................................................................................................................................

> Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications > Page 5869
Alternator: Mechanical Specifications
Pulley Ratio
Generator Type ....................................................................................................................................................................
Torque Specifications
Generator Mounting Bracket Bolts ......................................................................................................................................

> Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 5870
Alternator: Description and Operation

I CIRCUIT
The I (ignition) circuit:
- Turns the voltage regulator on when the ignition switch is in the RUN position.
- Turns the charge warning indicator on if there is a problem in the charging system.
A CIRCUIT
The A (battery sense) circuit:
- Senses the battery voltage. The voltage regulator uses this to determine the generator output.
- Supplies current to the generator field coil.
- Is ALWAYS HOT
- Is protected by a fuse in the power distribution box.
> Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Removal and Installation
Alternator: Service and RepairRemoval and Installation
REMOVAL
(GEN)
1. Disconnect battery ground cable.2. Disconnect the wire harness attachments to the generator and voltage regulato
INSTALLATION
20-30 Nm (15-22 Lb-Ft)

8-12 Nm (71-106 Lb-In)
7-9 Nm (62-79 Lb-In)
1. Position the generator on the engine.2. Install the generator mounting bolts. Tighten bolts to .3. Install generator m
> Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Removal and Installation > Page 5873
Alternator: Service and RepairCleaning and Inspection

1. Check the generator pulley for looseness on the generator rotor shaft and for cracks or other damage. Replace any
cracked or bent.
2. Check the front and rear housings for cracks, particularly in the webbed areas at the mounting ear. Replace a dama
> Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications
Voltage Regulator: Specifications

Regulator Type ................................................................................................................................................................ El
> Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Ava
Article No.99-24-2
11/29/99

> Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service
Packages Available > Page 5883


NOTE

^
^
NOTE

NOTE

NOTE
NOTE

> Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Cylinder Inoperative

NOTE:
REMOVAL
drill.
INSTALLATION
> Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Cylinder Inoperative > Page 5890
REMOVAL
INSTALLATION
> Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations
Transmission View

> Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 5894
> Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > Customer Interest: > 06-19-14 > Oct > 06 > Starting System- No Crank
Starter Cable: Customer InterestStarting System- No Crank Condition

TSB 06-19-14
10/02/06
NO CRANK / STARTER TERMINAL FATIGUE
FORD:1997-2007 Crown Victoria1997-2004 F-150 Heritage1997-2006 Expedition1998-2006 E-Series1999-2006 F-Su
LINCOLN:1998-2006 Navigator2003-2005 Aviator
MERCURY:1997-2007 Grand Marquis2002-2007 Mountaineer
ISSUESome vehicles may exhibit a no crank condition due to an open circuit in the starter relay to starter motor circuit
ACTIONFollow 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 co
NOTE
TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE KIT DOE
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 AN
Parts BlockWARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
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 IfAvailable
DEALER CODING
> Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > Customer Interest: > 06-19-14 > Oct > 06 > Starting
System- No Crank Condition > Page 5903

CONDITION
BASIC PART NO. CODE
14A280 01
Disclaimer
> Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-19-14 > Oct > 06 > Starting Syste
Starter Cable: All Technical Service BulletinsStarting System- No Crank Condition

TSB 06-19-14
10/02/06
NO CRANK / STARTER TERMINAL FATIGUE
FORD:1997-2007 Crown Victoria1997-2004 F-150 Heritage1997-2006 Expedition1998-2006 E-Series1999-2006 F-Su
LINCOLN:1998-2006 Navigator2003-2005 Aviator
MERCURY:1997-2007 Grand Marquis2002-2007 Mountaineer
ISSUESome vehicles may exhibit a no crank condition due to an open circuit in the starter relay to starter motor circuit
ACTIONFollow 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 co
NOTE
TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE KIT DOE
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 AN
Parts BlockWARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
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 IfAvailable
DEALER CODING
> Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-19-14 > Oct > 06 >
Starting System- No Crank Condition > Page 5909

CONDITION
BASIC PART NO. CODE
14A280 01
Disclaimer
> Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Cable: > 98-20-10 > Oct > 98 > E
Noise
Article No.98-20-10
10/12/98
^
^

SERVICE PROCEDURE
1.
NOTE

> Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Cable: > 98-20-10
> Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 5915

2.


W705949-S300 Worm clamp (3/4" To 4")
SUPERSEDES: 98-6-4


DEALER CODING
CONDITION
BASIC PART NO. CODE
5E258 33
OASIS CODES: 403000, 702000, 702100, 702200, 703000


2.


W705949-S300 Worm clamp (3/4" To 4")
SUPERSEDES: 98-6-4


DEALER CODING
CONDITION
BASIC PART NO. CODE
5E258 33
OASIS CODES: 403000, 702000, 702100, 702200, 703000

> Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Testing and Inspection
Starter Drive/Bendix: Testing and Inspection
Inspect the entire circumference of the flywheel ring gear for damage when the starter drive gear teeth are damaged. Th
> Starting and Charging > Starting System > Starter Relay > Component Information > Locations

> Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5931


- Pull-in coil
- Contacts


REMOVAL
INSTALLATION
> Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications
Starter Solenoid: Specifications
Solenoid Screws ...................................................................................................................................................................

> Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5942


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
Circuit Breaker 7
Circuit Breaker 17
Circuit Breaker 12
Circuit Breaker 14
> Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise S
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
^
RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPE
^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY
FORD:1990-1994 TEMPO1990-1997 ESCORT, PROBE, THUNDERBIRD1990-1998 MUSTANG1990-1999 TAUR
LINCOLN:1990-1992 MARK VII1990-1994 CONTINENTAL1990-2002 TOWN CAR1998-2003 NAVIGATOR2002
MERCURY:1990-1994 TOPAZ1990-1997 COUGAR1990-1999 SABLE1990-2002 GRAND MARQUIS1991-1997 T

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 el
ACTION
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fue
> 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 5958

NOTE
IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER
NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON
NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FF
TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise
1.
Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may
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
Parts Block
SUPERSEDES: 01-7-3
021604AA Diagnose And Install RFI 2.1 Hrs.
Filter 1990-1997Thunderbird/Cougar
021604BA Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1999 And 2001Taurus/Sable
021604CA Diagnose And Install RFI 1.2 Hrs.

Filter 1992-1997 CrownVictoria/GrandMarquis/Town Car
021604CB Diagnose And Install RFI 1.6 Hrs.

021604CC Diagnose And Install RFI 2.2 Hrs.
Filter 1998-2002 CrownVictoria/Grand Marquis
021604DA Diagnose And Install RFI 1.9 Hrs.


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.

021604GA Diagnose And Install RFI 1.5 Hrs.
Filter 1990-1994Continental
021604HA Diagnose And Install RFI 1.6 Hrs.

Filter 1990 Escort
021604IA Diagnose And Install RFI 0.8 Hr.
Filter 1991-1996 EscortTracer
021604IB Diagnose And Install RFI 1.6 Hrs.

Filter 1997 Escort/Tracer
021604JA Diagnose And Install RFI 0.8 Hr.
Filter 1997Contour/Mystique
021604JB Diagnose And Install RFI 1.8 Hrs.
Filter 1998-1999Contour/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.

021604MA Diagnose And Install RFI 1.6 Hrs.
Filter 1990-2002 EconolineSingle Fuel Tank
021604MB Diagnose And Install RFI 2.6 Hrs.
Filter 1990-1991 EconolineBoth 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.
021604PA Diagnose And Install RFI 1.5 Hrs.
Filter 1997-2002Mountaineer

Filter 1995-2002 Windstar
021604RA Diagnose And Install RFI 1.9 Hrs.

Filter 1993-2002 Villager

021604SA Diagnose And Install RFI 1.7 Hrs.
Filter 1997-2003Expedition/Navigator
021604TA Diagnose And Install RFI 1.3 Hrs.
Filter 1990-1997 RangerStandard Cab
021604TB Diagnose And Install RFI 1.8 Hrs.
Filter 1990-1997 RangerSuper Cab
021604TC Diagnose And Install RFI 1.8 Hrs.
Filter 1998-2002 Ranger4X4
021604TD Diagnose And Install RFI 1.6 Hrs.
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 1990-1996F-150/250/350/Super DutyAnd 1997 F-350/SuperdutyRear

021604WB Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1996F-150/250/350/Super DutyAnd 1997 F-350/SuperdutyFront
021604WC Diagnose And Install RFI 2.1 Hrs.
Filter 1990-1996F-150/250/350/Super DutyAnd 1997 F-350/SuperdutyBoth 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 SuperDuty F-Series: Front Tank
021604XC Diagnose And Install RFI 1.5 Hrs.
Filter 1999-2002 SuperDuty F-Series: Rear Tank
021604XD Diagnose And Install RFI 2.7 Hrs.
Filter 1999-2002 SuperDuty F-Series: Both Tanks
021604YA Diagnose And Install RFI 0.8 Hr.

Filter 2001-2002 Escape

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 Manu

2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Fig
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 H

NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE N
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK ARE

3.
On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery mod
a.
Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing o

NOTE
NOTE
WARNING
4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattlin
5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PART
6.
Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for th
7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual.
> Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Elect
Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers
Article No.02-16-4
08/19/02
^
^

ISSUE
ACTION
> 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 5971

NOTE
NOTE
NOTE
TEST PROCEDURE
1.
3.
Parts Block
SUPERSEDES: 01-7-3







Filter 1990 Escort













Filter 1998-2002 F-150




DEALER CODING
CONDITION
BASIC PART NO. CODE
18B925 42
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Service Procedure

c.

NOTE
NOTE
WARNING

3.
a.

NOTE
NOTE
WARNING
CAUTION
6.
> Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Page 5979
Electronic Noise Suppressor: Testing and Inspection

CAPACITOR
0.158 MFD
100 working volts DC.The radio voltage regulator capacitor connected across the heat sinks may be tested on a c
20 milli-ohmsIn the absence of a capacitor tester, the unit may be checked for shorts by means of an ohmmeter c
> Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5984


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
(PCM)
Air
FuseSuspension
1 System ........................................................................................................................................................

Power Distribution
Fuse 2
^ Starter Relay
^ Generator
^ Fuse 15
^ Fuse 18

Power Distribution
Fuse 3
^ Radio

Power Distribution
Fuse 4

Power Distribution
Fuse 5
^ Horn Relay

Power Distribution
Fuse 6

Power Distribution
Fuse 8

Power Distribution
Fuse 9
^ Fuse 5
^ Fuse 9

Power Distribution
Fuse 10
^ Fuse 1
^ Fuse 2
^ Fuse 6
^ Fuse 7
^ Fuse 10
^ Fuse 11
^ Fuse 13

Power Distribution
Fuse 11
^ Fuse 4
^ Fuse 8
^ Fuse 16

Power Distribution
Fuse 12
^ PCM Power Relay

Power Distribution
Fuse 13

Power Distribution
Fuse 14
^ Fuse 17

Power Distribution
Fuse 15

Power Distribution
Fuse 16

Power Distribution


Blower
Fuse 1 Motor........................................................................................................................................................................
^ Speed Control

Power Distribution

Power Distribution
Fuse 2

Power Distribution

Power Distribution
Fuse 4
^ Main Light Switch

Power Distribution

Power Distribution

Power Distribution
Fuse 5
^ Backup Lamps
^ Turn Signals
^ Air Suspension

^ Shift Lock
Power Distribution

Power Distribution
Fuse 6
^ Speed Control
^ Main Light Switch
^ Clock

Power Distribution

Power Distribution

Power Distribution
Fuse 7
^ Power Diode
^ Ignition Coils

Power Distribution

Power Distribution
Fuse 8
^ Power Mirrors
^ keyless Entry
^ Clock Memory

^ Power Windows
^ Police Spot Lamps
Power Distribution

Power Distribution
Fuse 9
^ Blower Motor

Power Distribution

Power Distribution
Fuse 10
^ Air bag Module

Power Distribution

Power Distribution
Fuse 11
^ Radio

Power Distribution

Power Distribution
Fuse 13
^ Warning Lamps

Power Distribution

Power Distribution

Power Distribution
Fuse 15

Power Distribution

Power Distribution
Fuse 16
^ Cigar Lighter

Power Distribution

Power Distribution
Fuse 17
^ Rear Defrost

Power Distribution

Power Distribution
Fuse 18
^ Air Bag Module

Power Distribution

Power Distribution
> Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations

Engine View
> Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6046


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:




(PCM)
Fuse 13 .................................................................................................................................................................................
Fuse 1

Power Distribution
Fuse 2
^ Starter Relay
^ Generator
^ Fuse 15
^ Fuse 18

Power Distribution
Fuse 3
^ Radio

Power Distribution
Fuse 4

Power Distribution
Fuse 5
^ Horn Relay

Power Distribution
Fuse 6

Power Distribution
Fuse 8

Power Distribution
Fuse 9
^ Fuse 5
^ Fuse 9

Power Distribution
Fuse 10
^ Fuse 1
^ Fuse 2
^ Fuse 6
^ Fuse 7
^ Fuse 10
^ Fuse 11
^ Fuse 13

Power Distribution
Fuse 11
^ Fuse 4
^ Fuse 8
^ Fuse 16

Power Distribution
Fuse 12
^ PCM Power Relay

Power Distribution
Fuse 13

Power Distribution
Fuse 14
^ Fuse 17

Power Distribution
Fuse 15

Power Distribution
Fuse 16

Power Distribution


Blower
Fuse 1 Motor........................................................................................................................................................................
^ Speed Control

Power Distribution

Power Distribution
Fuse 2

Power Distribution

Power Distribution
Fuse 4
^ Main Light Switch

Power Distribution

Power Distribution

Power Distribution
Fuse 5
^ Backup Lamps
^ Turn Signals
^ Air Suspension

^ Shift Lock
Power Distribution

Power Distribution
Fuse 6
^ Speed Control
^ Main Light Switch
^ Clock

Power Distribution

Power Distribution

Power Distribution
Fuse 7
^ Power Diode
^ Ignition Coils

Power Distribution

Power Distribution
Fuse 8
^ Power Mirrors
^ keyless Entry
^ Clock Memory

^ Power Windows
^ Police Spot Lamps
Power Distribution

Power Distribution
Fuse 9
^ Blower Motor

Power Distribution

Power Distribution
Fuse 10
^ Air bag Module

Power Distribution

Power Distribution
Fuse 11
^ Radio

Power Distribution

Power Distribution
Fuse 13
^ Warning Lamps

Power Distribution

Power Distribution

Power Distribution
Fuse 15

Power Distribution

Power Distribution
Fuse 16
^ Cigar Lighter

Power Distribution

Power Distribution
Fuse 17
^ Rear Defrost

Power Distribution

Power Distribution
Fuse 18
^ Air Bag Module

Power Distribution

Power Distribution
> Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6109


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:

Power Distribution
> Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101
In-Line Connector Faces - C101

> Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 > Page 6121

Multiple Junction Connector: Diagrams























> Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Police Power Relay

Engine View
> Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Police Power Relay > Page 6151





> Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Polic

Engine View
> Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information >
Locations > Police Power Relay > Page 6161





> Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay
> Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay
Relay Center (C110)

> Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay Center
> Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay Center > Page 6175
Relay Center (C110)

> Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > NHTSA08V051000 >
Incorrect Speed Control Jumper Harness
Wiring Harness: RecallsRecall 08V051000: Incorrect Speed Control Jumper Harness

> 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 6184

> Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: >
Recall 08V051000: Incorrect Speed Control Jumper Harness

> 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 6190

> Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6196


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
Circuit Breaker 7
Circuit Breaker 17
Circuit Breaker 12
Circuit Breaker 14
> Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > A
Buzzing Noise From Speakers
Article No.02-16-4
08/19/02
^
^

ISSUE
ACTION
> 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 6212

NOTE
NOTE
NOTE
TEST PROCEDURE
1.
3.
Parts Block
SUPERSEDES: 01-7-3







Filter 1990 Escort













Filter 1998-2002 F-150




DEALER CODING
CONDITION
BASIC PART NO. CODE
18B925 42
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Service Procedure

c.

NOTE
NOTE
WARNING

3.
a.

NOTE
NOTE
WARNING
CAUTION
6.
> Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor:
- Whining/Buzzing Noise From Speakers
Article No.02-16-4
08/19/02
^
^

ISSUE
ACTION
> 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 6225

NOTE
NOTE
NOTE
TEST PROCEDURE
1.
3.
Parts Block
SUPERSEDES: 01-7-3







Filter 1990 Escort













Filter 1998-2002 F-150




DEALER CODING
CONDITION
BASIC PART NO. CODE
18B925 42
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Service Procedure

c.

NOTE
NOTE
WARNING

3.
a.

NOTE
NOTE
WARNING
CAUTION
6.
> Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Page 6233
Electronic Noise Suppressor: Testing and Inspection

CAPACITOR
0.158 MFD
100 working volts DC.The radio voltage regulator capacitor connected across the heat sinks may be tested on a c
20 milli-ohmsIn the absence of a capacitor tester, the unit may be checked for shorts by means of an ohmmeter c
> Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6238


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
(PCM)
Air
FuseSuspension
1 System ........................................................................................................................................................

Power Distribution
Fuse 2
^ Starter Relay
^ Generator
^ Fuse 15
^ Fuse 18

Power Distribution
Fuse 3
^ Radio

Power Distribution
Fuse 4

Power Distribution
Fuse 5
^ Horn Relay

Power Distribution
Fuse 6

Power Distribution
Fuse 8

Power Distribution
Fuse 9
^ Fuse 5
^ Fuse 9

Power Distribution
Fuse 10
^ Fuse 1
^ Fuse 2
^ Fuse 6
^ Fuse 7
^ Fuse 10
^ Fuse 11
^ Fuse 13

Power Distribution
Fuse 11
^ Fuse 4
^ Fuse 8
^ Fuse 16

Power Distribution
Fuse 12
^ PCM Power Relay

Power Distribution
Fuse 13

Power Distribution
Fuse 14
^ Fuse 17

Power Distribution
Fuse 15

Power Distribution
Fuse 16

Power Distribution


Blower
Fuse 1 Motor........................................................................................................................................................................
^ Speed Control

Power Distribution

Power Distribution
Fuse 2

Power Distribution

Power Distribution
Fuse 4
^ Main Light Switch

Power Distribution

Power Distribution

Power Distribution
Fuse 5
^ Backup Lamps
^ Turn Signals
^ Air Suspension

^ Shift Lock
Power Distribution

Power Distribution
Fuse 6
^ Speed Control
^ Main Light Switch
^ Clock

Power Distribution

Power Distribution

Power Distribution
Fuse 7
^ Power Diode
^ Ignition Coils

Power Distribution

Power Distribution
Fuse 8
^ Power Mirrors
^ keyless Entry
^ Clock Memory

^ Power Windows
^ Police Spot Lamps
Power Distribution

Power Distribution
Fuse 9
^ Blower Motor

Power Distribution

Power Distribution
Fuse 10
^ Air bag Module

Power Distribution

Power Distribution
Fuse 11
^ Radio

Power Distribution

Power Distribution
Fuse 13
^ Warning Lamps

Power Distribution

Power Distribution

Power Distribution
Fuse 15

Power Distribution

Power Distribution
Fuse 16
^ Cigar Lighter

Power Distribution

Power Distribution
Fuse 17
^ Rear Defrost

Power Distribution

Power Distribution
Fuse 18
^ Air Bag Module

Power Distribution

Power Distribution
> Power and Ground Distribution > Fuse Block > Component Information > Locations

Engine View
> Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6300


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:




(PCM)
Fuse 13 .................................................................................................................................................................................
Fuse 1

Power Distribution
Fuse 2
^ Starter Relay
^ Generator
^ Fuse 15
^ Fuse 18

Power Distribution
Fuse 3
^ Radio

Power Distribution
Fuse 4

Power Distribution
Fuse 5
^ Horn Relay

Power Distribution
Fuse 6

Power Distribution
Fuse 8

Power Distribution
Fuse 9
^ Fuse 5
^ Fuse 9

Power Distribution
Fuse 10
^ Fuse 1
^ Fuse 2
^ Fuse 6
^ Fuse 7
^ Fuse 10
^ Fuse 11
^ Fuse 13

Power Distribution
Fuse 11
^ Fuse 4
^ Fuse 8
^ Fuse 16

Power Distribution
Fuse 12
^ PCM Power Relay

Power Distribution
Fuse 13

Power Distribution
Fuse 14
^ Fuse 17

Power Distribution
Fuse 15

Power Distribution
Fuse 16

Power Distribution


Blower
Fuse 1 Motor........................................................................................................................................................................
^ Speed Control

Power Distribution

Power Distribution
Fuse 2

Power Distribution

Power Distribution
Fuse 4
^ Main Light Switch

Power Distribution

Power Distribution

Power Distribution
Fuse 5
^ Backup Lamps
^ Turn Signals
^ Air Suspension

^ Shift Lock
Power Distribution

Power Distribution
Fuse 6
^ Speed Control
^ Main Light Switch
^ Clock

Power Distribution

Power Distribution

Power Distribution
Fuse 7
^ Power Diode
^ Ignition Coils

Power Distribution

Power Distribution
Fuse 8
^ Power Mirrors
^ keyless Entry
^ Clock Memory

^ Power Windows
^ Police Spot Lamps
Power Distribution

Power Distribution
Fuse 9
^ Blower Motor

Power Distribution

Power Distribution
Fuse 10
^ Air bag Module

Power Distribution

Power Distribution
Fuse 11
^ Radio

Power Distribution

Power Distribution
Fuse 13
^ Warning Lamps

Power Distribution

Power Distribution

Power Distribution
Fuse 15

Power Distribution

Power Distribution
Fuse 16
^ Cigar Lighter

Power Distribution

Power Distribution
Fuse 17
^ Rear Defrost

Power Distribution

Power Distribution
Fuse 18
^ Air Bag Module

Power Distribution

Power Distribution
> Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6363


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:

Power Distribution
> Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101

> Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 > Page 6375

Multiple Junction Connector: Diagrams























> Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Police Power Relay

Engine View
> Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Police Power Relay > Page 6405





> Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Police Power Relay

Engine View
> Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Police Power
Relay > Page 6415

> Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Police Power Relay > Page 64




> Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay Center
> Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay Center > Page 6424
Relay Center (C110)

> Power and Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay Center
> Power and Ground Distribution > Relay Box > Component Information > Diagrams > High Current Relay Center > Page 6429
Relay Center (C110)

> Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Recalls for Wiring Harness: > NHTSA08V051000 > Feb > 08 > Recall 08V05
Harness
Wiring Harness: RecallsRecall 08V051000: Incorrect Speed Control Jumper Harness

> 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 6438

> Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > NHTSA08V051000 > F
Incorrect Speed Control Jumper Harness

> 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 6444

> Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure
Article No.99-11-1
06/14/99
^
^
CONTENTS
> Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6450

GENERAL PROCEDURES
Diagnostic Theory

Diagnostic Process

Glossary of Terms

Dynamic Balance







a.
c.
d.

-
Vibrate Software(R)

ChassisEAR
EngineEAR


Tracing Powder
d.

Diagnostic Process




2. Pre-Drive Check
important
^
^
^
^
5. Road Test
Note:
^

speed-related.
^
^
^

^

Steering Input Test
^
Brake Test
^
^
^
^

^ WARNING:
^ CAUTION:

^
WARNING:
CAUTION:
Note:
^
^ Start the engine.
^ CAUTION:

1. Static operation
^
2. While cranking
3. At idle
^
^
1.
1. Speed related
-
-
-

-

-
-
Airvaries
Noise Leak with
wind/vehicle
2. Acceleration
-
4. Braking.
^
^
^
5. Clutching


6. Shifting
^
8. Cruising speeds
1.




































Pinpoint Tests































1. Open the hood.
2. Note:
Note:
4.
3. CAUTION:

3.
6.
7.

^

^


WARNING:
4. CAUTION:

WARNING:
WARNING:
Note:
1. WARNING:

CAUTION:
6.
^

Wheel Bearing Check
1. WARNING:

2. Note :

^
> Steering and Suspension > Alignment > System Information > Specifications > Alignment
Alignment: SpecificationsAlignment
NOTE: All specifications are given for a vehicle at curb height with 1/2 tank of fuel.
CAMBER:
Nominal ............................................................................................................................................................................
Nominal ......................................................................................................................................................................
CASTER:
Nominal ............................................................................................................................................................................
Nominal ......................................................................................................................................................................
TOTAL TOE [a]

Degree:
Nominal ......................................................................................................................................................................
mm/inch:
Nominal ......................................................................................................................................................................
CLEAR VISION [b]:
Nominal ............................................................................................................................................................................
TURNING ANGLE [c] ......................................................................................................................................................
[a]
[b]
20.Turning
[c]Positive valueangle at outside
is toe-in, wheel
negative with
value inside wheel turned
is toe-out.Position of steering wheel spoke to horizontal. Negative value spec
> Steering and Suspension > Alignment > System Information > Specifications > Alignment > Page 6547
Alignment: SpecificationsSuspension Height
1. Examine the vehicle for indications of abnormal attitude, such as the front or rear end being higher or lower than n
SUSPENSION HEIGHT
Front(#1) .....................................................................................................................................................................
SUSPENSION HEIGHT (w/ Air Suspension)
Front(#1) .....................................................................................................................................................................
SUSPENSION HEIGHT (w/ Handling Package)
Front(#1) .....................................................................................................................................................................
SUSPENSION HEIGHT (Police or CNG)
Front(#1) .....................................................................................................................................................................
Note #1: For front measurement, record measurement A (lowest point on suspension arm) and B (center of housing bo
> Steering and Suspension > Alignment > System Information > Specifications > Page 6548
> Steering and Suspension > Alignment > System Information > Specifications > Page 6549
> Steering and Suspension > Alignment > System Information > Service Precautions > Technician Safety Information
Alignment: Technician Safety Information
WARNING: DO NOT REMOVE AN AIR SPRING UNDER ANY CIRCUMSTANCES WHEN THERE IS PR
> Steering and Suspension > Alignment > System Information > Service Precautions > Technician Safety Information > Page 6552
Alignment: Vehicle Damage Warnings
WARNING: THE ELECTRICAL POWER SUPPLY TO THE AIR RIDE CONTROL SYSTEM MUST BE SH
NOTE:
Incorrect hoisting
Hoisting/Lifting - can damage steering linkage components and front suspension components.
-
Before hoisting/lifting turn the air suspension switch (if equipped) OFF. It is located in LH side of luggage co
> Steering and Suspension > Alignment > System Information > Service and Repair > Caster and Camber
Alignment: Service and RepairCaster and Camber
DESCRIPTION
PROCEDURE
> Steering and Suspension > Alignment > System Information > Service and Repair > Caster and Camber > Page 6555

required
-3/4 degree
to bringtovehicle
+3/4 degree
to nominal
Maximum
setting.-
camber difference between wheels (left minus right) to be within with
NOTE:
Alignment: Service and RepairComponent Inspections


Alignment: Service and RepairCurb Load
Alignment: Service and RepairPreliminary Inspection

DESCRIPTION
-
PROCEDURE
-
-
Before checking or adjusting front wheel alignment settings, the Accurate Trim Test must be performed. See: Sus
Alignment: Service and Repair
Caster and Camber
DESCRIPTION
PROCEDURE

required
-3/4 degree
to bringtovehicle
+3/4 degree
to nominal
Maximum
setting.-
camber difference between wheels (left minus right) to be within with
NOTE:
Component Inspections

Curb Load
Preliminary Inspection
DESCRIPTION
-
PROCEDURE
-
-
Before checking or adjusting front wheel alignment settings, the Accurate Trim Test must be performed. See: Sus
Steering Angle

NOTE: Perform the steering angle check before toe-in measurement (if any steering angle corrections have been made
DESCRIPTION
Steering
Check gear.steering angles at full right and left positions. If the angles are not within specification, the tie ro
the wheel
- Steering column.
- Intermediate shaft universal joints.
- Steering wheel.
Toe & Steering Wheel Centering (Clear Vision)

DESCRIPTION
After adjusting caster and camber, check the steering wheel spoke position with the front wheels in straight-ahead po
NOTE: Toe should only be checked and adjusted after the caster and camber have been adjusted to specification.
PROCEDURE
Check the toe with the front wheels in the straight-ahead position. Run the engine so the power steering control valve

1. Loosen the two clamp bolts on each front wheel spindle tie rod adjusting sleeve.
2. Adjust toe. If the steering wheel spokes are in their normal position, lengthen or shorten both rods equally to obtai
wheel spokes are not in their normal position make the necessary rod adjustments to obtain correct toe and steerin

Sleeve Position
3. When toe and the steering wheel spoke position are both correct, lubricate clamp, bolts and nuts. Tighten the clam
27-30 Nm (20-22 ft. lbs.).
spindle tie rod adjusting sleeves to The sleeve position should not be changed when the clamp bolts are tightened
Wheel Turning Angle

NOTE:
If the turning angle does not measure to specification, check the front suspension lower arm and other suspension or s
20,
If the
18.51. Theturning
turningangle
angledoes not measure
cannot to specification,
be adjusted check
directly because it isthe suspension,
a result frame
of caster, or steering
camber and toeparts for a bent
adjustments con
comb
> Steering and Suspension > Alignment > System Information > Service and Repair > Page 6564
Alignment: Tools and Equipment

-
1.59 mm (1/16-inch)
Equipment used for alignment inspection must be accurate. All wheel alignment readings must be performed on a
-
Install the wheel alignment equipment on the vehicle and follow the installation and inspection instructions provi
> Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations

> Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > With Air S

> Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information >
Diagrams > With Air Suspension > Page 6572

> Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > With Air S

> Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > Page 6574
TheAt low vehicle

andpump flow for
the shock full p
absorber
-
-
-
> Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > Page 6575
REMOVAL
INSTALLATION
> Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information >
Control)

Engine View
Control) > Page 6581

REMOVAL
INSTALLATION
> Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations

> Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page

> Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information >

DESCRIPTION
OPERATION
-
-
-
-
-
REMOVAL
INSTALLATION
> Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Specifications

> Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Specifications > Page 6

> Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Specifications > Page 6
An 30 rpmshock
- 60 rpm
- 30 rpm,
> Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > S
REMOVAL
INSTALLATION
> Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > S
REMOVAL
INSTALLATION
> Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Sp


DESCRIPTION
OPERATION
suspension frame
height crossmember
oneoperates
end andas
at follows:-
-
REMOVAL
INSTALLATION
> Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Specifications

> Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Specifications > Pag

> Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Specifications > Pag
An 30 rpmshock
- 60 rpm
- 30 rpm,
> Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair >
REMOVAL
INSTALLATION
> Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair >
REMOVAL
INSTALLATION
> Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Locations
> Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Locations > Page
NOTE:
> Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Locations > Page

REMOVAL
INSTALLATION
> Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Vehicle Speed Sensor Signal > Component Information > Specifications

Retaining Bolt ......................................................................................................................................................................
(VSS) (EVO)
TheThe output
vehicle current
speed to the
electronic whe
variable
- 600 mA. 600 mA
REMOVAL
(VSS)
INSTALLATION
> Steering and Suspension > Steering > Center Link > Component Information > Testing and Inspection
Center Link: Testing and Inspection
Replace the steering sector shaft arm drag link, connecting the steering gear sector shaft arm and the steering idler arm
> Steering and Suspension > Steering > Center Link > Component Information > Testing and Inspection > Page 6630
Center Link: Service and Repair

REMOVAL
1. Raise the vehicle on a hoist and install safety stands.2. Remove the cotter pins and nuts that retain inner tie rod end
arm from the steering sector shaft arm drag link using Tie Rod End Remover TOOL-3290-D or equivalent and re
5. Remove the cotter pin and nut retaining the steering idler arm and bracket to the steering sector shaft arm drag link
shaft arm drag link. Discard cotter pin.
INSTALLATION
1. Position the steering sector shaft arm drag link to the steering gear sector shaft arm and steering idler arm and brac
47-63 Nm (35-46 ft. lbs.).

retaining nuts. Place the steering idler arm and bracket and the front wheels in the straight-ahead position to main
69.5-80.5 Nm (52-59 ft. lbs.).2. Place the tie rod ends on the steering sector shaft arm drag link, and install the retain
Continue to tighten the nuts until the slots in the nuts align with the holes in the stud. Install a new cotter pin.
3. Remove the safety stands and lower the vehicle. Check toe and adjust if necessary.
4. Loosen the clamps from the front wheel spindle tie rod adjusting sleeve, and oil the front wheel spindle tie rod adj
27-29 Nm (20-21 ft. lbs.).nuts. Position the clamps. Tighten the clamp nuts to
> Steering and Suspension > Steering > Diagnostic Connector, Steering > Component Information > Locations
Diagnostic Connector: Locations

The Electronic Variable Orifice Test Connector is located at the RH side of the trunk.
> Steering and Suspension > Steering > Diagnostic Connector, Steering > Component Information > Locations > Page 6634
Electronic Variable Orifice Connector

> Steering and Suspension > Steering > Idler Arm > Component Information > Specifications
Idler Arm: Specifications
[a]Idler Arm and Bracket to Front Subframe Bolt ..............................................................................................................
[a] - Tighten to low limit of specification, the tighten nut to the nearest cotter pin slot and insert the cotter pin.
> Steering and Suspension > Steering > Idler Arm > Component Information > Specifications > Page 6638
Idler Arm: Service and Repair

REMOVAL
If the steering idler arm and bracket bushings are worn, replace the steering idler arm and bracket assembly as follow
INSTALLATION
68-92 Nm (51-67 ft. lbs.).

69.5-80.5 Nm (51-60 ft. lbs.)1. Install the bolts and nuts that retain the steering idler arm and bracket assembly to the
castellation with the cotter pin hole in the stud. Install a new cotter pin.
> Steering and Suspension > Steering > Pitman Arm > Component Information > Technical Service Bulletins > Steering - Pitman Arm Inspection Tip
Pitman Arm: Technical Service BulletinsSteering - Pitman Arm Inspection Tip
Article No.99-21-9
10/18/99
STEERING - PITMAN ARM INSPECTION - SERVICE TIP
ISSUEThe Workshop Manuals for 1998-2000 Crown Victoria/Grand Marquis and Town Car do not contain a procedur
ACTIONThe pitman arm ball joint on 1998-2000 Crown Victoria/Grand Marquis and Town Car vehicles can be inspec
INSPECTION PROCEDURE
2.
Visually inspect the pitman arm ball joint seal. If it is cut or torn, replace the pitman arm (refer to the appropriate
3.
Pull down on the centerlink to take any play out of the pitman arm ball joint. Measure the distance from the top o
4. If more than 2.78 mm (0.110") movement is measured, replace the pitman arm (refer to the appropriate Worksho
5. The nut attaching the pitman arm to the centerlink can be reused.

> Steering and Suspension > Steering > Pitman Arm > Component Information > Technical Service Bulletins > Page 6643
Pitman Arm: Specifications

Retaining Nut To Sector Shaft .............................................................................................................................................
Pitman Arm: Description and Operation
Theconnects
steering the
gearsteering gear arm:-
sector shaft to the steering sector shaft arm drag link.
- is splined at the steering gear end.
- uses a tapered spherical joint at the steering sector shaft arm drag link end.
Pitman Arm: Service and Repair

REMOVAL
1. Remove and discard the nut that retains the steering sector shaft arm drag link to the steering gear sector shaft arm
equivalent.
3. Remove the steering gear sector shaft arm retaining nut and lock washer.
4. Position the front wheels in the straight-ahead position, and remove the steering gear sector shaft arm using Pitman
INSTALLATION
1. With the front wheels in the straight-ahead position, place the steering gear sector shaft arm pointing rearward on
tooth on the steering gear sector shaft arm with the blind tooth on the sector shaft of the steering gear.
271-339 Nm (200-250 ft. lbs.). 69.5-80.5 Nm (52-59 ft. lbs.).2. Install the nut and lockwasher. Tighten to 3. Install t
> Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Air Bleeding
Power Steering Bleeding: Service and RepairAir Bleeding
74-79C (165-175F).If bubbles are present in the power steering fluid, bleed the system as follows:1. Fill the power s
CAUTION: Do not hold the steering wheel in the far left or right position, or damage to power steering pump m
3. Turn the steering wheel all the way to the left and right several times.4. Check the fluid level.5. If air is still trappe
> Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Air Bleeding > Page 6651
Power Steering Bleeding: Service and RepairPurging

NOTE:
If the air is not purged from the power steering system correctly a second customer concern or pump failure could resu
DESCRIPTION
All power
A whine, steering
shudder noise complaints
or squeak noise heard with
fromevidence ofsteering
the power aerated pump
fluid on pre-delivery
may be caused vehicles
by air in only, prior toThe
the system. anyf
- After any power steering system component (for example, gear, hose) has been replaced and the noise is heard
FILL PROCEDURE
1. Check and fill remote reservoir to center mark.2. Disable ignition by disconnecting the ignition coils and lift front
level.
NOTE: Do not hold steering wheel on stops.
4. Crank engine 30 seconds while cycling lock to lock.5. Check fluid level and add MERCON(r) Multi-Purpose (AT
VACUUM PURGE PROCEDURE
68-85 kPa (20-25 in. Hg)
68-85 kPa (20-25 in. Hg)1. Tightly insert the rubber stopper of the air evacuator assembly into pump reservoir.2. En
7. Cycle steering wheel from lock to lock every 30 seconds for approximately five minutes.8. Shut engine off, releas
Do not
NOTE: - hold steering wheel on stops.
- In severe cases it may be necessary to repeat air purge with vacuum source procedure.
10. Start engine and cycle steering wheel from lock to lock every 30 seconds for approximately five minutes.11. Chec
> Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage
Power Steering Fluid: Technical Service BulletinsSteering - Mercon V(R) Fluid Usage
TSB 07-1-7
01/22/07
MERCON(R) ATF REPLACED BY MERCON(R) V AS ASERVICE FLUID FOR SOME POWER STEERINGSYST
FORD:1996-1997 Thunderbird1996-2007 Crown Victoria, Mustang, Taurus1998-2003 Escort2000-2007 Focus2002-2
LINCOLN:1996-1998 Mark VIII1996-1999 Continental1996-2007 Town Car2000-2006 Lincoln LS2006 Zephyr2007

MERCURY:1996-1997 Cougar1996-2005 Sable1996-2007 Grand Marquis1999-2002 Cougar2003-2004 Marauder200
ISSUEMERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power s
> Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid
Usage > Page 6656

ACTIONBeginning immediately all power steering applications requiring MERCON(R) can now be serviced using ME
SERVICE PROCEDURE
Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmissio
CAUTION
APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLU
Parts Block
Disclaimer
> 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.
> Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 6659
Power Steering Fluid: Fluid Type Specifications

FLUID TYPE ........................................................................................................................................................... Ford
> Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Service and Repair > Fill Procedures
Power Steering Fluid: Service and RepairFill Procedures
Start-Up Procedure (After Service)

Part 1 Of 2
> Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Service and Repair > Fill Procedures > Page 6662

Part 2 Of 2
DESCRIPTION
This procedure is recommended whenever the power steering pump or power steering short rack is replaced.
MATERIALS REQUIRED
The101 kPa (30materials

following in. Hg). are required:-
A vacuum pump with gauge, capable of pulling The vacuum source should be a Rotunda Vacuum Tester 014
-
A No.7 stopper cap or a special power steering reservoir cap assembly with a tee connection, shutoff valves a
PREPARATION
1. Assemble the vacuum fill system.2. Install the vacuum fill system on the vehicle. If the power steering short rack o
to drain from the system.
3. Tighten all steering system and vacuum fill connections to specification. Do not over tighten or damage may resul
INITIAL FILL
1. Install the rubber stopper on power steering pump reservoir.2. Open valve No. 1 and allow the power steering fluid
steering pump reservoir.
84-101 kPa (25-30 in. Hg)

3 kPa (14. Close all valves.5. Open valves No. 3 and No. 5. Start the vacuum pump. Operate the pump until a gauge
in. Hg), there is a leak in the power steering or filling system that must be corrected.
84-101 kPa (25-30 in. Hg)
7. Startle vacuum pump. Open valve No. 5. Operate the pump until a gauge reading of is obtained.8. Close valve No
higher than the power steering pump and power steering pump reservoir.
9. When fluid stops draining from vacuum fill reservoir, close valve No.1 and remove cap or rubber stopper.
FINAL FILL
1. Adjust fluid level in power steering pump reservoir to correct level. There will be a slight drop in the level when th
steering wheel cycled.
2. Operate the engine at an idle for 15 minutes, then inspect for leaks. It will not be necessary to devac the system un
the power steering pump that could cause noise or affect performance.
Top Off
74-79C (165-175F). 1. Idle engine for two to three minutes to warm fluid to 2. Turn steering wheel all the way to the

3. Check fluid level(ATF)
Multi-Purpose in theTransmission
power steering pump reservoir. Fluid level should be between the MIN and MAX marks. I
Fluid.
> Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Service and Repair > Fill Procedures > Page 6663
Power Steering Fluid: Service and RepairFlushing

DESCRIPTION
Always flush the power steering system when replacing any component due to fluid contamination. Also flush th
PROCEDURE
1. Place the oil cooler-to-reservoir hose at remote reservoir in a container and plug the power steering return line clam
may be used.
2. Fill the vehicle remote power steering reservoir with MERCON(r) Multi-Purpose (ATF) Transmission Fluid.3. Di
the START position and crank the engine with the starter motor while turning the steering wheel from left to righ
5. When all the fluid has been added, turn ignition switch to the OFF position.6. Remove the plug from the power ste
7. Check fluid level. Add fluid if necessary.8. Crank engine and recheck fluid level. Add fluid as necessary.9. Lower
10. Start engine and turn steering wheel slowly from lock-to-lock several times. Check fluid level and adjust as requir
> Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Locations
> Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Locations > Page 6667
Power Steering Fluid Reservoir: Description and Operation
The CIII power steering pump has a filter built into the power steering pump reservoir. Check for contamination and cl
> Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Locations > Page 6668
Power Steering Fluid Reservoir: Service and Repair
REMOVAL
1. Drain the reservoir using a hand suction pump.2. Disconnect the power steering reservoir pump hose and the powe
INSTALLATION
1. Follow the removal procedure in reverse order.2. Fill and leak check the system.
> Steering and Suspension > Steering > Power Steering > Power Steering Hydraulic Cylinder > Component Information > Locations
> Steering and Suspension > Steering > Power Steering > Power Steering Hydraulic Cylinder > Component Information > Locations > Page 6672
Power Steering Hydraulic Cylinder: Service and Repair
1. Remove and disassemble steering gear.2. Remove the plastic ring and the O-ring from the piston and ball nut.3. D
> Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Ho
Wheel - Vibration/Buzzing Noise On Right Turns
Power Steering Line/Hose: Customer InterestSteering Wheel - Vibration/Buzzing Noise On Right Turns
Article No.98-25-8
12/21/98
^
^
SERVICE PROCEDURE
VERIFY THE CONCERN
NOTE
5.

^ One (1) Bolt - M6-1.00x12.5
^ One (1) Nut - M6x1.0
> Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power
Steering Line/Hose: > 98-25-8 > Dec > 98 > Steering Wheel - Vibration/Buzzing Noise On Right Turns > Page 6681

^ One (1) Bolt - M6-1.00x12.5
^ One (1) Nut - M6x1.0
^ One (1) Nut - M6x1.0

SUPERSEDES: 97-18-5

Pressure Hose
DEALER CODING
CONDITION
BASIC PART NO. CODE
3A719 55
OASIS CODES: 303000, 702000, 702100, 703000, 703100

> Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Ste
98 > Steering Wheel - Vibration/Buzzing Noise On Right Turns
Power Steering Line/Hose: All Technical Service BulletinsSteering Wheel - Vibration/Buzzing Noise On Right T
Article No.98-25-8
12/21/98
^
^
SERVICE PROCEDURE
VERIFY THE CONCERN
NOTE
5.

^ One (1) Bolt - M6-1.00x12.5
^ One (1) Nut - M6x1.0
> Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Power Steering Line/Hose: > 98-25-8 > Dec > 98 > Steering Wheel - Vibration/Buzzing Noise On Right Turns > Page 6687

^ One (1) Bolt - M6-1.00x12.5
^ One (1) Nut - M6x1.0
^ One (1) Nut - M6x1.0

SUPERSEDES: 97-18-5

Pressure Hose
DEALER CODING
CONDITION
BASIC PART NO. CODE
3A719 55
OASIS CODES: 303000, 702000, 702100, 703000, 703100

> Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Page 6688
Power Steering Line/Hose: Specifications

Pressure Hose
To Pump ...........................................................................................................................................................................
Return Hose
To Gear .............................................................................................................................................................................
Power Steering Line/Hose: Description and Operation
TheBetween the power

power steering steering
pressure andpressure hoseatorthe
return hose power steering
power return
steering pumphose
usesand the hose
O-ring sealsnut
at the quick connect fitting
- Between the hose nut and the cast iron steering gear housing or power steering pressure, return and pump outlet l
Power Steering Line/Hose: Testing and Inspection
- The power steering hoses use O-ring seals at the quick connect fittings. There are two possible leak points at the
- A leak might occur between the (power steering pressure hose or power steering return hose ) and the hose nut.
-
A leak might occur between the hose nut and the aluminum steering gear housing or power steering pressure, retu
> Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose Fittings, Pressure and Return Line at Gear and P
Power Steering Line/Hose: Service and RepairHose Fittings, Pressure and Return Line at Gear and Pump
If a leak occurs between the tubing and tube nut, replace the power steering pressure hose and power steering return ho

1. Check the steering gear housing fitting and power steering pump valve outlet fitting to determine which fitting is l
between power steering pressure hose nut and power steering pump valve outlet fitting.
CAUTION: To prevent damage, don not over tighten.
2. If the leak is between the power steering pressure hose nut and the steering gear housing or power steering pump v
34-46 Nm (26-33 ft. lbs.)make sure the nuts are tightened to at the steering gear.
3. If the leak continues or if the leak is between power steering pressure hose and the power steering pressure hose nu
pressure hose.
4. Unscrew the power steering pressure hose nut and inspect the Teflon seal. Always replace the Teflon seal when th
removed. To facilitate assembly of the new Teflon seal, a tapered shaft may be required to stretch the washer so i
5. The rubber O-ring at the pump cannot be serviced with this design. If leak is due to the O-ring, replace the power s
rubber O-rings at the steering gear are serviceable.
The power steering pump valve outlet fitting is fully engaged only when the power steering pressure hose bottoms in th
Power Steering Line/Hose: Service and RepairHose Fittings, Pressure and Return, Seal Replacement
If a leak occurs between the tubing and the tube nut, replace the power steering pressure hose and the power steering re
16-24 Nm (12-18 ft. lbs.).1. Check to make sure the nuts are tightened to Do not overtighten.
2. If leak continues, inspect for the following conditions:

- Damaged O-ring.
- Cracked or damaged convolution of tube end and sealing surfaces
- Damaged sealing surface in valve housing (step which supports tube and O-ring)
16-24 Nm (12-17 ft. lbs.)3. Replace the O-ring. Also replace the pressure line or valve housing if indicated by the in
Power Steering Line/Hose: Service and RepairPressure Hose

REMOVAL
1. Disconnect battery ground cable. 2. Remove power steering pressure hose fitting at power steering pump reservoir
INSTALLATION
16-24 Nm (12-17 ft. lbs.).

16-24 Nm (12-17 ft. lbs.).
34-46 Nm (26-33 ft. lbs.).
1. Position power steering pressure hose and power steering return hose in vehicle.2. Connect power steering pressur
Power Steering Line/Hose: Service and RepairQuick Connect Power Steering Fitting Seal Replacement
34-46 Nm (26-33 ft. lbs.).

1. Check the fitting to determine whether the leak is between the tube and tube nut or between the tube nut and the po
If a leak occurs between the tubing and tube nut, replace the power steering pressure hose and tube nut. If a leak occurs
4. Unscrew the tube nut and inspect plastic seal washer. Always replace the plastic seal washer when the power steer
facilitate assembly of new plastic seal washer, a tapered shaft such as a teflon seal replacer set 211-D027 (D90P-
5. The rubber O-ring cannot be serviced with this design. If leak is due to the O-ring, replace the power steering pres
> Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose Fittings, Pressure and Return
Line at Gear and Pump > Page 6697

34-46 Nm (26-33 ft. lbs.).6. Connect tube nut and tighten to
The quick connect fitting may disengage if not fully assembled, if the snap ring is missing, or if the tube nut or the hose
If the fitting disengages, replace the power steering pressure hose. The fitting is fully engaged only when the power ste
> Steering and Suspension > Steering > Power Steering > Variable Assist Control Valve <--> [Power Steering Pressure Control Valve] > Component Information > Specifications
Variable Assist Control Valve: Specifications

Retaining Bolts ....................................................................................................................................................................
> Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications
Power Steering Pump: Mechanical Specifications

Retaining Bolts ....................................................................................................................................................................
> Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 6705
Power Steering Pump: Pressure, Vacuum and Temperature Specifications

Relief Pressure .....................................................................................................................................................................
> Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 6706
Power Steering Pump: Capacity Specifications

FLOW RATES
Minimum Flow [a] ...........................................................................................................................................................
[a] At zero speed (vehicle not moving).
[b] At 1500 RPM.
NOTE:
Flow depends on pump model, engine idle RPM, and pulley ratio. Engine idle RPM must be set to specification wh
> Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 6707
Power Steering Pump: Application and ID
An identification tag attached to the power steering pump indicates the model number and bar code. Refer to these whe
Type: CIIIModel: HBD-AA

> Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 6708
Power Steering Pump: Description and Operation
NORMAL OPERATION
TheItCIII
is a power
belt driven, vane-type
steering power
pump has steering pump.
the following features:-
- It is mounted directly to the engine block by four retaining bolts.
- (EVO)
An electronic variable orifice power steering control valve actuator is connected to the pump body to control spe
- The electrical connector and casing are able to swivel. This is normal and does not indicate a loose power steerin
- The power steering oil reservoir for the power steering fluid is mounted on the LH apron.
-
An identification tag attached to the power steering pump indicates the model number and bar code. Refer to thes
- The power steering pump is serviced as an assembly. If any service is required, the entire power steering pump as
-
The only exception is if the power steering control valve actuator or connector on the power steering pump assem
FAIL SAFE
(EVO)
In the event of an electrical circuit malfunction, such as circuit open, shorted, or electronic variable orifice contro
PRESSURE RELIEF VALVE OPERATION
Located in the power steering pump valve body, the pressure relief valve limits hydraulic pressure within the pow
> Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Power Steering Pump: Initial Inspection and Diagnostic Overview

- Wash all parts, except seals, in a suitable solvent and dry with compressed air. Do not submerge or allow solvent
- Inspect mounting surfaces for nicks or cracks.
- Check housing for cracks or dents. Threaded holes should be checked for damaged threads. Service or replace po
NOTE:
The only serviceable components on the steering pump are the EVO power steering control valve actuator and the pre
> Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 671
Power Steering Pump: Component Tests and General Diagnostics
Prechecks
Before performing pump flow and pressure test, complete the following checks for conditions which could cause loss o
1. Check power steering pump reservoir for proper fluid level.2. Check tires for correct air pressure.3. Check drive b
If the above items are correct or have been corrected and the loss of assist still exists, test power steering pump fl
Procedure
1. To connect the analyzer into the steering system remove the pressure fitting from the power steering pump and con
adapter of the analyzer.
20 Nm (15 ft. lbs.)

2. Thread the other adapter of the analyzer into the power steering pump.3. Connect the analyzer to the adapters. Tig
approximately two minutes at idle.
NOTE: The vehicle must not be moving during the following checks.
5. Record the following:
78 2C (172 5F). 78 2C (172 5F)a. Flow, liters/minute (gallons/minute) at b. Pressure, kPa (psi) at at idle with the
- 7.5 liters/min. (2.0 gallons/minute),
If flow is below the power steering pump may require service. However, at this point, continue thediagno
- 1034 kPa (150 psi)If pressure is above check hoses for restrictions.
5100 kPa (740 psi). 78 2C (172 5 F).6. Partially close the gate valve to build up Observe and record flow (liters/min
- 5.7 liters/minute (1.4 gallons/minute),If flow drops below replace power steering pump.
7. Completely close and partially open the gate valve three times. (Do not allow the valve to remain closed for more
8275-9653 kPa (1200-1400 psi)record pressure, kPa (psi). Pressure specification should maintain a current press
> Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Testing and Inspection > Initial Inspection and Diagnostic

If the pressure
maximum. recordedrecorded
If the pressure is aboveisthe maximum
lower than thespecification listed, replace
minimum specification power
listed, steering
replace the pump.
power steering pum
8. Increase the engine speed from idle to approximately 1500 rpm. Observe and record flow, liters/minute (gallons/m
- If flow exceeds the maximum free flow specification, replace the power steering pump.
9. Check idle speed and set if necessary. With the engine at idle, turn (or have an assistant turn) the steering wheel to
the Pressure
pressure developed
and flow atatstops.-
both stops should be nearly the same as the maximum pump output pressure.
- 1.9 liters/minute (0.5 gallon/minute).
1.9L/minute (0.5 gallon/minute)
At the same time, flow should drop below If pressure does not reach maximum output or flow does notdrop b
10. Turn (or have an assistant turn) steering wheel slightly in both directions, and release quickly while watching the p
should move from the normal back pressure reading and snap back as the steering wheel is released. If it comes b
11. Disconnect and remove analyzer and connect lines.
SYSTEM BACK-PRESSURE
1034 kPa (150 psi),
If pressure is above check hoses for restrictions. If the pressure is above the maximum specification listed, the fl
MINIMUM PUMP FLOW
If the flow drops to a level lower than the value in the power steering pump specification chart, replace the power
RELIEF PRESSURE TEST

6 liters/minute (1.6 gallons/minute),
If flow is below the power steering pump may require service. However, at this point, continue diagnosis.Refer t
INTERNAL LEAKAGE TEST

1.9 liters/minute (0.5 gallons/minute),
If the pressure does not reach maximum output or flow does not drop below excessive internal leakage isoccurrin
Test Equipment
REQUIRED EQUIPMENT
- Engine tachometer
- Thermometer: -17.8 to 149C (0 to 300F)
- Rotunda Power Steering System Analyzer 211-F001 (014-00207) or equivalent
- Set of adapter fittings (part of 211-F001 (014-00207))
DESCRIPTION
TheSystem back pressure.

test procedure used in conjunction with the Rotunda Power Steering System Analyzer 014-00207 or equivale
- Power steering pump flow.
- Steering gear internal leakage.
- Power steering pump relief pressure.
TheRestriction in hoses
interpretation of theorabove
fittings
readouts will determine which of the following conditions or components are the
- Sticking gear valve.
- Inefficient pump cam pack.
- Sticking relief valve.
- Binding in suspension.
Leaks
When looking for leaks, use this procedure to pinpoint the exact cause and location to avoid misdiagnosis:1. Check f
housing to see the leak.
CAUTION:
Do not hold the steering wheel against a stop for more than three to five seconds at a time, as damage to power s
> Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Testing and Inspection > Initial Inspection and Diagnostic

6. Some leaks are high-pressure leaks and may require holding steering wheel against stops (not more than five secon
CAUTION:
Do not hold the steering wheel against a stop for more than three to five seconds at a time, as damage to power s
Part 1 Of 2
Part 2 Of 2
> Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation
Power Steering Pump: Service and RepairRemoval and Installation
REMOVAL
1. Remove drive belt.2. Raise vehicle on hoist.
WARNING: TURN AIR SUSPENSION SWITCH (LOCATED IN LUGGAGE COMPARTMENT) OFF
3. Remove power steering pressure hose bracket.4. Disconnect electrical connector at power steering control valve ac
5. Install Steering Pump Pulley Remover T69L-10300-B on the pulley hub.
CAUTION: Do not apply in-and-out pressure on the power steering pump shaft. Pressure will damage the intern
> Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 6716

6. Hold the small hex-head and rotate the tool nut counterclockwise to remove the power steering pump pulley.7. Dis
10. Remove power steering pressure switch from pump.
INSTALLATION
1. Position the power steering pump on the mounting bosses of engine block and install the bolts at the side of the po
20-30 Nm (15-22 ft. lbs.).
2. Connect the power steering reservoir pump hose to the power steering pump and reposition the hose clamp to pow
34-46 Nm (26-33 ft. lbs.).open-end wrench. Tighten to
NOTE: Swivel or end play of the power steering pressure hose end is normal and does not indicate a loose fittin
5. Place the power steering pump pulley on the power steering pump shaft and install Power Steering Pump Pulley R
small diameter threads on the tool should be engaged in the power steering pump shaft.
CAUTION: Do not apply in and out pressure on the shaft. Pressure will damage the internal rotating group.
6. Hold the small hex-head and rotate the tool nut clockwise to install the power steering pump pulley on the shaft.
CAUTION: Do not apply in and out pressure on the shaft. Pressure will damage the internal rotating group.
NOTE: 0.25 mm (0.010 inch) The power steering pump pulley face must be flush within of the end of the pum
7. Remove the Power Steering Pump Pulley Replacer T91P-3A733-A.8. Remove the shipping tube nut from power s
11. Install power steering pressure hose bracket.11. Lower the vehicle.12. If equipped, turn the air suspension ON.13.
Power Steering Pump: Service and RepairFlushing
(ATF)
1.9 liters (0.5 gal)If contamination is found in the power steering system, flush the power steering pump as follows:1
As soon as all fluid has been added, turn the ignition switch to the OFF position.
6. Connect the power steering pressure hose at the power rack and pinion steering gear.7. Check the fluid level.8. Cra
remains constant.
9. Lower vehicle and connect the ignition coil wire.
10. Start the engine and turn the steering wheel from lock-to-lock to expel any air trapped in the system. This will rest
CAUTION: Do not hold the steering wheel against a stop for more than five seconds at a time, as damage to po
Power Steering Pump: Service and RepairPriming

PRIMING BEFORE INSTALLATION
The replacement power steering pump must be primed with the specified power steering fluid prior to installation
1. Remove the fitting from the pressure port and pour power steering fluid into the pressure port with the port facing
of fluid added to the power steering pump.
2. Turn the power steering pump driveshaft slowly during this procedure to allow more fluid to enter the power steer
PRIMING ON VEHICLE
1. When the unprimed replacement power steering pump has been mounted to the engine, connect the plumbing line
power steering pump reservoir and fill the power steering pump reservoir to the proper level.
2. Raise the front of the vehicle until both front wheels are off the ground.3. Start the vehicle and slowly make stop-t
level.
5. Lower front of vehicle and check power steering system for proper operation.
FILL PROCEDURE
1. Check and fill remote reservoir to center mark.2. Disable ignition by disconnecting the ignition coils and lift front
level.
4. Crank engine 30 seconds while cycling lock to lock.5. Check fluid level and add MERCON(r) Multi-Purpose (AT
> Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Locations
> Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Locations > Page 6722
Power Steering Valve: Description and Operation
DESCRIPTION
-
The power steering control valve actuator is located on the power steering pump below the engine on the LH side
- This differential pressure is used to control the spool valve in the CIII power steering pump.
-
The power steering control valve actuator/spool valve regulates the hydraulic flow and when combined with a cu
- The EVO Power Steering Control Valve Actuator generates a differential pressure, dependent on flow and curren
-
In the event of an electrical circuit malfunction such as circuit open, shorted, or control module failure, the actuat
OPERATION
The16
output
km/hcurrent
(10 mph)
to the
60power
mA steering control valve actuator is a function of vehicle speed and the steering whe
When vehicle speed is less than the power steering control valve actuator output current is less than and full
- 40 km/h (25 mph), 300 mA.As vehicle speed increases to the current increases linearly to
- 142 km/h (88 mph), 590 mA.
590 mA 142 km/h (88 mph).As vehicle speed continues to increase up to the current increases linearly to Th
- Conversely, as vehicle speeds decrease, the current decreases at the linear rate.
> Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Locations > Page 6723
Power Steering Valve: Service and Repair
REMOVAL
1. Remove power steering pump.2. Place power steering pump in vise. Remove EVO power steering control valve ac
the back of the power steering control valve actuator.
INSTALLATION
14-20 Nm (11-14 ft. lbs.).

1. Install EVO power steering control valve actuator to power steering pump. Tighten to 2. Install power steering pum
> Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations

> Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Diagrams > With Air Suspension

> Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Diagrams > With Air Suspension > Page 6729

> Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Diagrams > With Air Suspension > Page 6730

> Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Diagrams > Page 6731
TheAt low vehicle

andpump flow for
the shock full p
absorber
-
-
-
> Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Diagrams > Page 6732
REMOVAL
INSTALLATION
> Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations

> Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > With Air Suspension

> Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > With Air Suspension > Page 6739

> Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > With Air Suspension > Page 6740

> Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > Page 6741
TheAt low vehicle

andpump flow for
the shock full p
absorber
-
-
-
> Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > Page 6742
REMOVAL
INSTALLATION
> Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Specifications

> Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Specifications > Page 6747

> Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Specifications > Page 6748
An 30 rpmshock
- 60 rpm
- 30 rpm,
> Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Sensor
REMOVAL
INSTALLATION
> Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Sensor > Page 6751
REMOVAL
INSTALLATION
> Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Specifications

> Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Specifications > Page 6755

> Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Specifications > Page 6756
An 30 rpmshock
- 60 rpm
- 30 rpm,
> Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Sensor
REMOVAL
INSTALLATION
> Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Sensor > Page 6759
REMOVAL
INSTALLATION
> Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming

WARNING:^
air bag module.
one minute (ECS)

WARNING:^
air bag module.

> Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page
6765

> Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 6766

> Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair
Steering Column Cover: Service and Repair
REMOVAL
1. Remove four screws retaining upper steering column shroud and lower steering column shroud.2. Remove upper s
INSTALLATION
> Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
Steering Gear: Specifications

OPERATION SPECIFICATIONS
Type ..................................................................................................................................................................................
Sector Gear Tooth Mesh Load), Max [1] ...................................................................................................................
TIGHTENING SPECIFICATIONS
[2]
Ball Return Guide Clamp .................................................................................................................................................

[1] Nominal over off center gear preload.
[2]
Specified torque, because the length of the tool required to torque the nut will affect the reading on the torque wr
Formula
(Length of Torque Wrench x Specification)/(Length of Torque Wrench + Special tool length) = Torque (using
Example:
13 xof98Torque
Length (72)/(13 + 5.5) == 13
Wrench 67 in.Length
Nm (50 ft.oflbs.)
Special Tool = 5.5 in.Specification = 98 Nm (72 ft. lbs.)^
Result
67 Nm (50 ft. lbs.).The specified torque reading should be
> Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 6773
Part 1 Of 2
Steering Gear: Application and ID
Steering gears are identified by a dot matrix identification tag on the gear housing. Dot matrix tags contain information
Steering Gear: Description and Operation
TheItsteering
is a torsion-bar
gear hastype of hydraulic
the following assisted system. The system furnishes power to reduce the amount of effort re
features:-
- It also reduces road shock and vibration.
- It includes a worm and one-piece piston which is meshed to the gear teeth on the steering sector shaft.
- It includes a rotary-style hydraulic valve consisting of:
- an input shaft.
- control valve sleeve.
- torsion bar.
- The valve is pinned to the worm and the input shaft is connected to the worm through the torsion bar.
-
The hydraulic action is generated by a relative rotary position between the power steering gear input shaft and co
> Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Steering Gear: Initial Inspection and Diagnostic Overview
1. Inspect the sector shaft bearing in the cover. If damaged or loose, replace sector shaft cover assembly.2. Inspect th
0.127-0.254 mm (0.005-0.010 inch).
3. Inspect the valve housing for wear, scoring or burrs.4. Inspect the valve housing and pressure and return ports for
The bearing cannot be serviced separately.
6. Check the fluid passages for obstruction or leakage.7. Inspect the gear housing for cracks and stripped threads and
replace the housing. Surface burnishing is acceptable if no significant step can be felt.
8. Make sure input shaft bearing rotates freely.9. Check the input shaft for freedom of movement in the sleeve. If mo
10. Inspect the piston rack and sector shaft teeth for nicks and burrs. Stone-off as required.
> Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6779
Steering Gear: Component Tests and General Diagnostics

Vehicles With 0-8045 km (0-5000 miles)
Checking:
45Reset if maximum on-center gear assembly preload measured while rocking input shaft over center is equal
Reset:
0.56-1.02 Nm (5-9 inch lbs.) 45Set torque measured rocking across center to a value greater than that measu
Vehicles With MORE Than 8045 km (5000 miles)Or Where The Sector Shaft Has Been Replaced
Checking:
45Reset if maximum on-center gear assembly preload measured while rocking input shaft over center is equal
Reset:
0.56-1.02 Nm (5-9 inch lbs.) 45Set torque measured rocking across center to a value greater than that measu
> Steering and Suspension > Steering > Steering Gear > Component Information > Testing and Inspection > Page 6780
Steering Gear: Adjustments
Part 1 Of 2
DESCRIPTION
During the vehicle break-in period, some factory adjustments may change. These changes will not necessarily aff
PROCEDURE
1. Disconnect the steering gear sector shaft arm from the steering gear sector shaft.2. Disconnect the fluid power stee
discharge the fluid from the steering gear.
approximately one-quarter turn from the 45 degree position. Refer to Meshload Checking and Setting under Spec
6. Turn the steering wheel back to center and determine the torque required to rotate the steering gear sector shaft ba
1.47-2.49 Nm (13-22 inch lbs.),
position. If the reading is not between loosen the nut and turn the adjuster screw until the reading is correct.Tigh
7. Check the readings and replace the steering gear sector shaft arm and steering wheel hub cover.8. Connect the pow
45
4. Turn the steering wheel to from the left stop.5. Using a Nm (inch pound) torque wrench on the steering wheel nut
> Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement
Steering Gear: Service and RepairReplacement

REMOVAL
1. Remove steering shaft U-joint shield.2. Tag power steering pressure hose and power steering return hose for future
prevent entry of dirt.
4. Remove the clamp bolt retaining the steering column intermediate shaft coupling to the steering gear.5. Raise vehi
CAUTION: Do not damage the seals or steering gear housing. Do not use a non-approved tool such as a pickle
6. Remove the steering gear sector shaft arm from the steering gear sector shaft with Pitman Arm Puller T64P-3590-
steering gear sector shaft arm.
7. Support the steering gear. Remove the steering gear retaining bolts.8. Work the steering gear free of the steering c
INSTALLATION
1. Turn the steering wheel to the straight-ahead position.
2. Center the power steering gear input shaft and control with the centerline of the two indexing flats at four o'clock a
66-90 Nm (49-66 ft. lbs.).the frame side rail. Install steering gear retaining bolts. Tighten to
4. Make sure the wheels are in the straight-ahead position. Install the steering gear sector shaft arm on the steering ge
270-340 Nm (200-250 ft. lbs.).lockwasher and nut. Tighten nut to
5. Move the steering column intermediate shaft coupling into place on the power steering gear input shaft and contro
27-41 Nm (20-30 ft. lbs.).to
10. Start the engine and turn the steering wheel from left to right. Inspect for fluid leaks.11. Install steering shaft U-joi
6. Connect the power steering pressure hose and power steering return hose to the steering gear. Tighten the lines.7.
> Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 6783
Steering Gear: Service and RepairDisassembly and Assembly

DISASSEMBLY
1. Remove snap ring from lower end of steering gear housing.
2. Remove power steering gear sector shaft dust seal using Puller T58L-101-B. Discard the seal.3. Remove power ste
NOTE: The bearing is not a separately serviceable item; it is part of the steering gear housing.
ASSEMBLY
1. Lubricate the new steering gear sector shaft housing oil seal and power steering gear sector shaft dust seal with cle
DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-A and ESR-M1C159-A.
2. Apply Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-A and ES
seal bore.
3. Place the new power steering gear sector shaft dust seal on Sector Shaft Seal Replacer T77L-3576-A so the raised
sector shaft dust seal is toward the tool.
3. Place the oil
housing steering gear sector
seal should shaft housing
be against oil seal
the flat side onpower
of the the tool with lipgear
steering away fromshaft
sector the tool. The flat back side of th
dust seal.
4. Insert the Sector Shaft Seal Replacer T77L-3576-A into the sector shaft bore and drive the tool until the steering g
and power steering gear sector shaft dust seal clear the snap ring groove.
CAUTION:
Do not bottom steering gear sector shaft housing oil seal and power steering gear sector shaft dust seal against b
5. Install snap ring in the groove in the steering gear housing.

Steering Gear: Service and RepairDisassembly
1. Remove steering gear.2. Hold the steering gear upside down over a drain pan and cycle the power steering gear in
drain the fluid from the steering gear.
3. Using mounting pads for support, secure the steering gear in Bench Mounted Holding Fixture T57L-500-B.4. Rem
NOTE: Centerline of the two indexing flats should be facing in the four o'clock position.
6. Remove the sector shaft cover bolts.7. Tap the lower end of the steering gear sector shaft with a soft-faced hamme
steering gear sector shaft as an assembly from the steering gear housing. Discard the O-ring.
8. Turn the steering gear sector shaft housing cover counterclockwise to remove the steering gear sector shaft housin
adjuster screw. Hold screw with screwdriver if necessary.
9. Remove valve housing retaining bolts and identification tag. Separate valve housing from steering gear housing w
it from spinning off the shaft. Remove the valve housing-to-steering gear housing O-ring. Discard O-rings.
NOTE:
If valve housing seals are to be replaced, proceed to Step 11. If the sector shaft seals are to be replaced, refer to
10. With the piston held so the ball guide faces up, remove the ball guide clamp screws and the ball guide clamp. With
ball guide, turn the piston so the ball guide faces down over a clean container. Let the guide tubes drop into the co
11. Rotate the power steering gear input shaft and control from stop-to-stop, until all the balls fall from the piston into
assembly can then be removed from the piston. Inspect the piston bore to make sure all the balls have been remov
Input Shaft Removal
12. Install the valve body assembly in Bench Mounted Holding Fixture T57L-500-B and loosen the Allen head race n
Remove the worm bearing race nut using Adjuster and Locknut Wrench T66P-3553-B and Spacer-Valve Housin
NOTE: The worm cannot be unscrewed from the piston.
13. Carefully slide the power steering gear input shaft and control, worm and valve assembly out of the valve housing
Steering Gear: Service and RepairAssembly
1. Mount the valve housing in Bench Mounted Holding Fixture T57L-500-B with the flanged end up.2. Apply a ligh
NOTE:
Before assembling components into the valve housing, liberally coat seal lips with Multi-Purpose Grease DOAZ
3. Carefully install the valve/worm assembly in the steering gear housing.

75-120 Nm (56-88 ft. lbs.)4. Refer to special torque procedure described below. Install the race nut in the steering ge
using Adjuster and Locknut Wrench T66P-3553-B and Spacer-Valve Housing to Piston T66P-3553-C.
1-2 Nm (9-17 inch lbs.). 5. Install the Allen head race nut setscrew through the valve housing. Tighten to 6. Place th
the center of the piston.

7. Place the steering gear ball return guide in the piston. Turning the worm clockwise, as viewed from the input end o
as removed in Step 11 in the steering gear ball return guide. A minimum of 27 balls is required. If all the balls ha
5-7 Nm (45-61 inch8. Secure the steering gear ball return guides in the ball nut with the steering gear ball return guid
lbs.).
9. Apply petroleum jelly to the seal on the piston.
10. Place a new O-ring on the valve housing.11. Slide the piston and valve into the steering gear housing.12. Align the
steering gear housing. Install the identification tag onto bolt. Install, but do not tighten, the retaining bolts. The bo
40-60 Nm (30-44 ft. lbs.).

13. Rotate the ball nut so the teeth are in the same plane as the sector teeth. Tighten the valve housing bolts to 14. Inst
61-75 Nm (45-55 ft. lbs.).the steering gear housing. Rotate the power steering gear input shaft and control one tu
1.47-2.49 Nm (13-22 inch lbs.).16. Using a Nm (inch-pound) torque wrench, adjust the gear meshload to
Steering Gear: Service and Repair
Replacement
REMOVAL
1. Remove steering shaft U-joint shield.2. Tag power steering pressure hose and power steering return hose for future
prevent entry of dirt.
4. Remove the clamp bolt retaining the steering column intermediate shaft coupling to the steering gear.5. Raise vehi
CAUTION: Do not damage the seals or steering gear housing. Do not use a non-approved tool such as a pickle
6. Remove the steering gear sector shaft arm from the steering gear sector shaft with Pitman Arm Puller T64P-3590-
steering gear sector shaft arm.
7. Support the steering gear. Remove the steering gear retaining bolts.8. Work the steering gear free of the steering c
INSTALLATION
1. Turn the steering wheel to the straight-ahead position.
2. Center the power steering gear input shaft and control with the centerline of the two indexing flats at four o'clock a
66-90 Nm (49-66 ft. lbs.).the frame side rail. Install steering gear retaining bolts. Tighten to
4. Make sure the wheels are in the straight-ahead position. Install the steering gear sector shaft arm on the steering ge
270-340 Nm (200-250 ft. lbs.).lockwasher and nut. Tighten nut to
5. Move the steering column intermediate shaft coupling into place on the power steering gear input shaft and contro
27-41 Nm (20-30 ft. lbs.).to
6. Connect the power steering pressure hose and power steering return hose to the steering gear. Tighten the lines.7.
10. Start the engine and turn the steering wheel from left to right. Inspect for fluid leaks.11. Install steering shaft U-joi
Disassembly and Assembly

DISASSEMBLY
1. Remove snap ring from lower end of steering gear housing.

2. Remove power steering gear sector shaft dust seal using Puller T58L-101-B. Discard the seal.3. Remove power ste
NOTE: The bearing is not a separately serviceable item; it is part of the steering gear housing.
ASSEMBLY
1. Lubricate the new steering gear sector shaft housing oil seal and power steering gear sector shaft dust seal with cle
DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-A and ESR-M1C159-A.
2. Apply Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-A and ES
seal bore.
3. Place the new power steering gear sector shaft dust seal on Sector Shaft Seal Replacer T77L-3576-A so the raised
sector shaft dust seal is toward the tool.
3. Place the steering gear sector shaft housing oil seal on the tool with lip away from the tool. The flat back side of th
housing oil seal should be against the flat side of the power steering gear sector shaft dust seal.
4. Insert the Sector Shaft Seal Replacer T77L-3576-A into the sector shaft bore and drive the tool until the steering g
and power steering gear sector shaft dust seal clear the snap ring groove.
CAUTION:
Do not bottom steering gear sector shaft housing oil seal and power steering gear sector shaft dust seal against b
5. Install snap ring in the groove in the steering gear housing.
Disassembly
1. Remove steering gear.2. Hold the steering gear upside down over a drain pan and cycle the power steering gear in
drain the fluid from the steering gear.
3. Using mounting pads for support, secure the steering gear in Bench Mounted Holding Fixture T57L-500-B.4. Rem

NOTE: Centerline of the two indexing flats should be facing in the four o'clock position.
6. Remove the sector shaft cover bolts.7. Tap the lower end of the steering gear sector shaft with a soft-faced hamme
steering gear sector shaft as an assembly from the steering gear housing. Discard the O-ring.
8. Turn the steering gear sector shaft housing cover counterclockwise to remove the steering gear sector shaft housin
adjuster screw. Hold screw with screwdriver if necessary.
9. Remove valve housing retaining bolts and identification tag. Separate valve housing from steering gear housing w
it from spinning off the shaft. Remove the valve housing-to-steering gear housing O-ring. Discard O-rings.
NOTE:
If valve housing seals are to be replaced, proceed to Step 11. If the sector shaft seals are to be replaced, refer to
10. With the piston held so the ball guide faces up, remove the ball guide clamp screws and the ball guide clamp. With
ball guide, turn the piston so the ball guide faces down over a clean container. Let the guide tubes drop into the co
11. Rotate the power steering gear input shaft and control from stop-to-stop, until all the balls fall from the piston into
assembly can then be removed from the piston. Inspect the piston bore to make sure all the balls have been remov
Input Shaft Removal
12. Install the valve body assembly in Bench Mounted Holding Fixture T57L-500-B and loosen the Allen head race n
Remove the worm bearing race nut using Adjuster and Locknut Wrench T66P-3553-B and Spacer-Valve Housin
NOTE: The worm cannot be unscrewed from the piston.
13. Carefully slide the power steering gear input shaft and control, worm and valve assembly out of the valve housing
Assembly

1. Mount the valve housing in Bench Mounted Holding Fixture T57L-500-B with the flanged end up.2. Apply a ligh
NOTE:
Before assembling components into the valve housing, liberally coat seal lips with Multi-Purpose Grease DOAZ
3. Carefully install the valve/worm assembly in the steering gear housing.

75-120 Nm (56-88 ft. lbs.)4. Refer to special torque procedure described below. Install the race nut in the steering ge
using Adjuster and Locknut Wrench T66P-3553-B and Spacer-Valve Housing to Piston T66P-3553-C.
1-2 Nm (9-17 inch lbs.). 5. Install the Allen head race nut setscrew through the valve housing. Tighten to 6. Place th
the center of the piston.

7. Place the steering gear ball return guide in the piston. Turning the worm clockwise, as viewed from the input end o
as removed in Step 11 in the steering gear ball return guide. A minimum of 27 balls is required. If all the balls ha
5-7 Nm (45-61 inch8. Secure the steering gear ball return guides in the ball nut with the steering gear ball return guid
lbs.).
9. Apply petroleum jelly to the seal on the piston.
10. Place a new O-ring on the valve housing.11. Slide the piston and valve into the steering gear housing.12. Align the
steering gear housing. Install the identification tag onto bolt. Install, but do not tighten, the retaining bolts. The bo
40-60 Nm (30-44 ft. lbs.).

13. Rotate the ball nut so the teeth are in the same plane as the sector teeth. Tighten the valve housing bolts to 14. Inst
61-75 Nm (45-55 ft. lbs.).the steering gear housing. Rotate the power steering gear input shaft and control one tu
1.47-2.49 Nm (13-22 inch lbs.).16. Using a Nm (inch-pound) torque wrench, adjust the gear meshload to
Cleaning
1. Use a clean workbench and tools.2. Clean the exterior of the steering gear with solvent. If necessary, drain off exc
Flushing
NOTE:
- Always flush steering gear when replacing the power steering pump due to fluid contamination.
-
The CIII power steering pump has a filter built into the power steering pump reservoir. Check for contamination
PROCEDURE
1. Remove the power steering pump and power steering pump pulley and service the pump.
NOTE: Flush the pressure line before installing. Connect only the pressure hose.
2. Install
starterthe power
motor steering
while pump
turning pulley
steering on the
wheel power
from steering pump. Install the power steering pump.3. Place the fl
lock-to-lock.
7. When all fluid has been added, turn ignition switch to OFF position and connect ignition coil wire.8. Remove plug
clamp behind bump in nipple.
9. Check fluid level. Add fluid if necessary.
NOTE: Do not overfill power steering pump reservoir.
10. Lower vehicle.11. Start engine and turn steering wheel slowly from lock-to-lock several times. Check fluid level a

Piston Disassembly and Assembly
1. Remove and disassemble steering gear.2. Remove the plastic ring and the O-ring from the piston and ball nut.3. D
Valve Housing Disassembly and Assembly
Valve Housing
DISASSEMBLY
1. Remove the power steering gear input shaft seal from the rear of the valve housing using Puller T58L-101-B. Disc
input shaft seal.
2. Remove the snap ring from the valve housing.3. Turn the fixture so the valve housing is upside down.
4. Insert Input Shaft Bearing/Seal Tool T65P-3524-A in the valve body assembly opposite the power steering gear in
power steering gear input shaft bearing and power steering gear input shaft seal out of the housing. Discard the po

CAUTION: Do not damage the valve bore in the housing when inserting and removing the tool.
ASSEMBLY
1. Coat the power steering gear input shaft bearing and power steering gear input shaft seal surface of the housing wi
2. Install the power steering gear input shaft bearing with the metal side that covers the rollers facing outward. Seat t
shaft bearing using Input Shaft Bearing/Seal Tool T65P-3524-A. Make sure power steering gear input shaft beari
3. Dip a new power steering gear input shaft seal in Power Steering Fluid Motorcraft MERCON(r) ATF.4. Place the
behind the undercut in the power steering gear input shaft and control.
5. Place the snap ring in the housing and drive the snap ring until ring seats in its groove.6. Apply a liberal coating of
ESR-M1C159-A to the area between the two seals.
7. Place the power steering gear input shaft seal in the housing with the rubber side facing out. Drive the power steer
behind the undercut in the power steering gear input shaft and control.
> Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Page 6794
Steering Gear: Tools and Equipment

> Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Page 6795

> Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications
Steering Shaft: Specifications
Lower Steering Column Shaft Bolt ..................................................................................................................................

Steering Column Shaft Pinch Bolt .............................................................................................................................
Boot Retaining Nuts .........................................................................................................................................................
> Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications > Page 6799
Steering Shaft: Service and Repair

REMOVAL
1. Remove bolt from upper steering column intermediate shaft coupling. Collapse steering column intermediate shaft
CAUTION:
Be sure the steering column is in the locked position or the lower end of the steering column is wired in such a w
3. Remove bolt retaining lower steering column shaft to steering gear input shaft.4. From inside of vehicle, remove lo
INSTALLATION
25-35 Nm (19-251. Turn secondary steering column tube boot inside out and position over three mounting studs.2. In
ft. lbs.).
5-7 Nm (45-61 inch lbs.). 3. Install primary steering column tube boot over lower steering column shaft and down o
25-35 Nm (19-25 ft. lbs.).bolt to
6. Check steering column for proper operation.
> Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Specifications
Steering Shaft Coupler: Specifications

Flex Coupling to Gear Input Shaft Bolt ...............................................................................................................................
> Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Specifications > Page 6803
Steering Shaft Coupler: Service and Repair

REMOVAL
1. Remove two steering column lower yoke bolts and slide steering column lower yoke down lower steering column
lower bearing retainer.
2. Remove steering column lower yoke from lower steering column shaft.
INSTALLATION
> Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications
Steering Wheel: Specifications

GENERAL
[1]
[2]Free Play, Max. ............................................................................................................................................................
[3]Retaining Bolt .............................................................................................................................................................
[1] Steering wheel turning effort. Engine running. Fluid at operating temperature.
[2] Lock to Lock.
[3] Use new steering wheel retaining bolt.
> Steering and Suspension > Steering > Steering Wheel > Component Information > Testing and Inspection > Free Play
Steering Wheel: Testing and InspectionFree Play

NOTE:
Before checking steering wheel free play, check for radial play or wobble between the steering wheel and steering col
1. With the wheels in the straight ahead position and engine off, gently turn the steering wheel to the left and right un
detected to check free play.
6 mm (1/4-inch)
2. Free play should not exceed measured at the outside diameter of the steering wheel.3. If the free play exceeds this
steering wheel looseness or column looseness.
> Steering and Suspension > Steering > Steering Wheel > Component Information > Testing and Inspection > Free Play > Page 6809
Steering Wheel: Testing and InspectionRadial Play
When checking steering wheel free play, also check for radial play or wobble between the steering wheel and steerin
> Steering and Suspension > Steering > Steering Wheel > Component Information > Testing and Inspection > Free Play > Page 6810
Steering Wheel: Testing and InspectionTurning Effort Check

NOTE: Make sure the front wheels are properly aligned and tire pressure is correct before checking turning effort.
43-49C (110-120F).
1. Park vehicle on dry concrete and set the parking brake.2. Idle the engine for two or three minutes. Turn the steerin
3.4 kg (7.5 lbs.).required to turn the steering wheel one complete revolution in each direction. Pull scale reading
> Steering and Suspension > Steering > Steering Wheel > Component Information > Testing and Inspection > Page 6811
Steering Wheel: Service and Repair

REMOVAL
1. Center front wheels to the straight-ahead position.
WARNING: THE BACKUP POWER SUPPLY MUST BE DISCONNECTED BEFORE ANY AIR BAG
2. Remove the driver air bag module.3. Disconnect air bag sliding contact electrical connector from steering wheel.4
CAUTION:
Be sure contact assembly wire harness does not get caught on steering wheel assembly when lifting off shaft to
5. Install Steering Wheel Puller 211-014 (T67L-3600-A) and remove steering wheel. Route contact assembly wire ha
steering wheel is lifted off the steering column shaft assembly.
INSTALLATION
1. Make sure the front wheels are in the straight-ahead position.2. Route contact assembly wire harness through steer
shaft assembly. The steering wheel and steering column shaft assembly marks should be aligned. Make sure air b
CAUTION: Be sure wiring does not get trapped between steering wheel and air bag sliding contact or air bag m
34-46 Nm (25-33 ft. lbs.).

3. Install new steering wheel retaining bolt and tighten to 4. Connect air bag sliding contact electrical connector to st
> Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications
Tie Rod End: Specifications

[a]
Castellated Nuts ..............................................................................................................................................................
[a] - Tighten to low limit of specification, the tighten nut to the nearest cotter pin slot and insert the cotter pin.
> Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Tie Rod End: Initial Inspection and Diagnostic Overview
1. Inspect the tie rod end or end for damage and the front suspension steering ball stud dust seal for cracks.2. Inspect
> Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6818
Tie Rod End: Component Tests and General Diagnostics

NOTE: This check may be done with the power rack and pinion steering gear on or off the vehicle:
8.9 N and 45 N (2 lbs. and 10 lbs.),1. Disconnect tie rod end from the front wheel spindle using Tie Rod End Remo
> Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Replacement
Tie Rod End: Service and RepairReplacement
REMOVAL
Use the following procedure to replace a worn or damaged front wheel spindle tie rod adjusting sleeve.1. Remove th
the inner and outer tie rod end should be threaded equally into the front wheel spindle tie rod adjusting sleeve.
INSTALLATION
47-63 Nm1. Position the tie rod end assembly on the steering sector shaft arm drag link and front wheel spindle. Inst
(35-46 ft. lbs.). Continue to tighten nut to align its next castellation with the cotter pin hole in the stud. Install a n
NOTE: Do not tighten the clamp bolts until after setting toe.
2. Check toe and adjust if necessary. Loosen the clamps from the front wheel spindle tie rod adjusting sleeve, and oil
adjusting sleeve, clamps, bolts and nuts.
27-29 Nm (20-21 ft. lbs.).3. Position the clamps. Tighten the clamp nuts to
> Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Replacement > Page 6821
Tie Rod End: Service and RepairTie Rod End

REMOVAL
1. Raise vehicle. Remove the cotter pin and nut from the tie rod end. Discard cotter pin.
2. Loosen the tie rod adjusting sleeve clamp bolts, and remove the tie rod end from the front wheel spindle or steerin
using Tie Rod End Remover TOOL-3290-D or equivalent.
3. Remove the tie rod end assembly from the front wheel spindle tie rod adjusting sleeve assembly, counting the num
NOTE: Discard all parts removed from the front wheel spindle tie rod adjusting sleeve assembly.
INSTALLATION
1. Thread a new tie rod end into the front wheel spindle tie rod adjusting sleeve assembly, using the same number of
in Step 3, Removal. Do not tighten the sleeve clamp bolts until after setting toe.
47-63 Nm (35-462. Install the tie rod end stud to the front wheel spindle or steering sector shaft arm drag link. Instal
ft. lbs.), then continue tightening nut to align its next castellation with the cotter pin hole in the stud. Install a new
3. Check toe and adjust if necessary. Loosen the clamps from the front wheel spindle tie rod adjusting sleeve, and oil
27-29 Nm (20-21 ft. lbs.).adjusting sleeve, clamps, bolts and nuts. Position the adjusting sleeve clamps. Tighten
> Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > NHTSA98V32200 > Jan > 99 > Recall 98V322000:
Ball Joint: RecallsRecall 98V322000: Lower Ball Joint Cracking
NHTSA CAMPAIGN ID Number: 98V322000Component: SUSPENSION: INDEPENDENT FRONT CONTROL AR

Manufacturer: FORD MOTOR COMPANY
Year: 1999Make: FORDModel: CROWN VICTORIAYear of Recall: '98Type of Report: VehiclePotential Number of
Summary:
Vehicle Description: Certain 1996-1999 Ford Crown Victoria police, fleet, natural gas, and 1996-1999Lincoln Town C
to drop to the ground.
If this occurs while the vehicle is moving, reduced steering control could occur, increasing the risk of acrash.
Dealers will replace the lower control arm ball joints
(2). Owner notification is expected to begin January 18, 1999.Owners who take their vehicles to an authorized dealero
> Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > NHTSA98V322000 > Jan > 99 > Recall 98V322000
Ball Joint: RecallsRecall 98V322000: Lower Ball Joint Failure
Year: 1999Make: FORDModel: CROWN VICTORIAYear of Recall: '98Type of Report: Vehicle Potential Number of
Summary:Vehicle Description: On certain police, fleet, natural gas, and limousine vehicles, the one-piece bearing with
If this occurs while the vehicle is moving, reduced steering control could occur, increasing the risk of a crash.
Dealers will replace the lower control arm ball joints (2).
Owner notification is expected to begin January 18, 1999. Owners who take their vehicles to an authorized dealer on an
> Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front Lower Control A
Recall - Front Lower Control Arm Ball Joint Replacement
SAFETY RECALL98337
Front Suspension Lower Control Arm Ball Joint Replacement - Certain 1990 through 1999 Ford Crown Victoria Police
^ Original - December, 1998
^ Important Recall Information
^ Dealer Letter
^
Administrative
^ Refund Codes
^
Labor Allowances
Attachment II^
^
TechnicalIII^
^ Customer Notification Letter - 1995 And Forward Vehicles
^ Customer Notification Letter - 1994 And Prior Vehicles
^ Supplement # 1 - February, 1999
^ Dealer Letter
^ Supplement # 2 - April, 1999
Announcing the Availability of Parts for 1994 and Prior Affected Vehicles
^ Dealer Letter
^
Labor Allowance
Attachment II^
> Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Recalls for Ball Joint: > 98S37 > Dec > 98 > Recall - Front
Lower Control Arm Ball Joint Replacement > Page 6839



DEALER-OWNER CONTACTOwners of affected vehicles according to Ford Motor Company records will be notified
OASISUse OASIS to determine if a vehicle is eligible for this recall.
PLEASE NOTE:
PROMPTLY CORRECTAffected vehicles on the enclosed list.
Other eligible vehicles which are brought to your dealership.
-- an owner cannot be contacted.
-- an owner does not make a service date.
CLAIMS SUBMISSIONEnter claims using DWE. See ACESII Manual, Sections 5 and 6. If towing is required, submit
REFUNDSSee ACESII Manual, Section 3-63 for submission procedures.
For owner-paid front suspension lower control arm ball joint replacement made before the date of the Owner Letter (or
Program Code - 98S37
Misc. Expense - 0.2 Hrs.

LABOR ALLOWANCES
PARTS REQUIREMENTS
-- Order Processing Center
-- DOESII
-- Updated Price Book
1995 Model Year and Foward Crown Victoria and Town Car
SERVICE PROCEDURE
The following service procedure will replace the left side lower ball joint. Repeat the procedure to replace the right side
1. Open hood.

2. Disconnect front wheel ABS sensor electrical connector. See Figure 1.
3. Route front wheel ABS sensor wiring into wheel well.
4. Raise and support vehicle.
5. Remove left front tire and wheel assembly.

6. Remove caliper anchor bracket retaining bolts. See Figure 2.
NOTE:

Do not let caliper assembly hang from brake hose.
7. Remove caliper and caliper anchor bracket as an assembly. Using wire, secure assembly away from steering knuc
8. Remove brake rotor from hub. Place mark on rotor and hub to aid in assembly.
9. Using 1/4 inch drill, drill out rivets securing brake rotor dust shield.
10. Remove brake rotor dust shield.
11. Remove retaining nut, then separate upper part of stabilizer bar link from steering knuckle.
12. Remove cotter pin from tie-rod castle nut.
13. Remove tie-rod castle nut, then separate tie-rod from steering knuckle.
14. Position jack stand under lower control arm.
15. Completely remove lower ball joint stud nut.
16. Reinstall lower ball joint stud nut a maximum of two (2) turns.
17. Remove jack stand supporting lower control arm.
18. Separate ball joint stud from steering knuckle.
20. Remove lower ball joint stud nut.

21. Using a block of wood for support, position steering knuckle away from lower control arm. See Figure 3.

22. Install Ball Joint Remover D89P-3010-A, Receiving Cup D84P-3395-A4 and U-Joint Tool T74P-4635-C on low
NOTE:
Use only hand tools to press ball joint out of lower control arm.
23. Using installed tools and a breaker bar, press ball joint out of lower control arm.
24. Remove tools and ball joint from lower control arm.

25.
Install Ball Joint Replacer T8OT-3010-A3, Receiving Cup D84P-3395-A4, U-Joint Tool T74P-4635-C and new
NOTE:
Use only hand tools to press ball joint into lower control arm.
26. sing installed tools and a breaker bar, press ball joint into lower control arm.
27. Remove tools from lower control arm.
28. Reposition jack stand toward end of control arm.
29. Position steering knuckle on lower ball joint stud. Raise jack stand as necessary to fully seat steering knuckle on
30. Install ball joint stud nut. Tighten to 148-201 Nm (110-148 lb-ft).
32.
Install tie-rod end into steering knuckle. Tighten castle nut to 47-63 Nm (35-46 lb-ft). Continue to tighten castle n
33. Install new cotter pin in tie-rod castle nut.
34. Install upper part of stabilizer bar link into steering knuckle. Tighten retaining nut to 26-35 Nm (20-25 lb-ft).
35. Using rivets, install brake rotor dust shield.
36. Install brake rotor on hub.
37. Install caliper and caliper anchor bracket as an assembly. Tighten anchor bracket mounting bolts to 170-230 Nm
38. Route the front wheel ABS sensor wiring into engine compartment.
39. Install left front tire and wheel assembly.
40. Lower vehicle.
41. Connect front wheel ABS sensor electrical connector.
42. Repeat procedure for right side lower ball joint.
43. With engine OFF, pump up brake system.
1994 Model Year and Prior Crown Victoria and Town Car
SERVICE PROCEDURE
1. Open hood.

2. Disconnect front wheel ABS sensor electrical connector, if applicable.See Figure 1.
3. Route front wheel ABS sensor wiring into wheel well, if applicable.

NOTE:

11. Remove retaining nut and bolt, then separate upper part of stabilizer bar link from steering knuckle.
15. Remove cotter pin and loosen castle nut one (1) or two (2) turns.
16. Remove lack stand supporting lower control arm.
19. Remove lower ball joint stud castle nut.


21. Install Ball Joint Remover D89P-301 0-A, Receiving Cup D84P-3395-A4 and U-Joint Tool T74P-4635-C on low
NOTE:

24.
Install Ball Joint Replacer T8OT-301O-A3, Receiving Cup D84P-3395-A4, U-Joint Tool T74P-4635-C and new
NOTE:
25. Using installed tools and a breaker bar, press ball joint into lower control arm.
29. Install ball joint stud castle nut. Tighten castle nut to 108-162 Nm (80-119 lb-ft). Continue to tighten castle nut un
30. Install new cotter pin in lower ball joint castle nut.
32.
33. Install new Cotter pin in tie-rod castle nut.
34. Install upper part of stabilizer bar link into steering knuckle. Tighten retaining nut to 40-55 Nm (30-40 lb4t).
38. Route the front wheel ABS sensor wiring into engine compartment, if applicable.
40. Lower vehicle.
41. Connect front wheel ABS sensor electrical connector, if applicable.







Supplement # 2 - Attachment II - Labor and Parts Information

LABOR ALLOWANCES
-- Order Processing Center DOESII
> Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > NHTSA98V32200 > Jan > 9
Joint Cracking
Ball Joint: All Technical Service BulletinsRecall 98V322000: Lower Ball Joint Cracking

Year: 1999Make: FORDModel: CROWN VICTORIAYear of Recall: '98Type of Report: VehiclePotential Number of
Summary:
Vehicle Description: Certain 1996-1999 Ford Crown Victoria police, fleet, natural gas, and 1996-1999Lincoln Town C
to drop to the ground.
If this occurs while the vehicle is moving, reduced steering control could occur, increasing the risk of acrash.
Dealers will replace the lower control arm ball joints
(2). Owner notification is expected to begin January 18, 1999.Owners who take their vehicles to an authorized dealero
> Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > NHTSA98V322000 > Jan >
Joint Failure
Ball Joint: All Technical Service BulletinsRecall 98V322000: Lower Ball Joint Failure
Year: 1999Make: FORDModel: CROWN VICTORIAYear of Recall: '98Type of Report: Vehicle Potential Number of
Summary:Vehicle Description: On certain police, fleet, natural gas, and limousine vehicles, the one-piece bearing with
If this occurs while the vehicle is moving, reduced steering control could occur, increasing the risk of a crash.
Dealers will replace the lower control arm ball joints (2).
Owner notification is expected to begin January 18, 1999. Owners who take their vehicles to an authorized dealer on an
> Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec > 98 > Recall -
Replacement
Recall - Front Lower Control Arm Ball Joint Replacement
SAFETY RECALL98337
^ Original - December, 1998
^ Important Recall Information
^ Dealer Letter
^
Administrative
^ Refund Codes
^
Labor Allowances
Attachment II^
^
TechnicalIII^
^ Customer Notification Letter - 1995 And Forward Vehicles
^ Customer Notification Letter - 1994 And Prior Vehicles
^ Supplement # 1 - February, 1999
^ Dealer Letter
^ Supplement # 2 - April, 1999
Announcing the Availability of Parts for 1994 and Prior Affected Vehicles
^ Dealer Letter
^
Labor Allowance
Attachment II^
> Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 98S37 > Dec
> 98 > Recall - Front Lower Control Arm Ball Joint Replacement > Page 6871



DEALER-OWNER CONTACTOwners of affected vehicles according to Ford Motor Company records will be notified
OASISUse OASIS to determine if a vehicle is eligible for this recall.
PLEASE NOTE:
PROMPTLY CORRECTAffected vehicles on the enclosed list.
Other eligible vehicles which are brought to your dealership.
-- an owner cannot be contacted.
-- an owner does not make a service date.
CLAIMS SUBMISSIONEnter claims using DWE. See ACESII Manual, Sections 5 and 6. If towing is required, submit
REFUNDSSee ACESII Manual, Section 3-63 for submission procedures.
For owner-paid front suspension lower control arm ball joint replacement made before the date of the Owner Letter (or
Program Code - 98S37
Misc. Expense - 0.2 Hrs.

LABOR ALLOWANCES
PARTS REQUIREMENTS
-- Order Processing Center
-- DOESII
1995 Model Year and Foward Crown Victoria and Town Car
SERVICE PROCEDURE
1. Open hood.

2. Disconnect front wheel ABS sensor electrical connector. See Figure 1.
3. Route front wheel ABS sensor wiring into wheel well.

NOTE:

11. Remove retaining nut, then separate upper part of stabilizer bar link from steering knuckle.
15. Completely remove lower ball joint stud nut.
16. Reinstall lower ball joint stud nut a maximum of two (2) turns.
20. Remove lower ball joint stud nut.


22. Install Ball Joint Remover D89P-3010-A, Receiving Cup D84P-3395-A4 and U-Joint Tool T74P-4635-C on low
NOTE:

25.
Install Ball Joint Replacer T8OT-3010-A3, Receiving Cup D84P-3395-A4, U-Joint Tool T74P-4635-C and new
NOTE:
26. sing installed tools and a breaker bar, press ball joint into lower control arm.
30. Install ball joint stud nut. Tighten to 148-201 Nm (110-148 lb-ft).
32.
33. Install new cotter pin in tie-rod castle nut.
34. Install upper part of stabilizer bar link into steering knuckle. Tighten retaining nut to 26-35 Nm (20-25 lb-ft).
38. Route the front wheel ABS sensor wiring into engine compartment.
40. Lower vehicle.
41. Connect front wheel ABS sensor electrical connector.
1994 Model Year and Prior Crown Victoria and Town Car
SERVICE PROCEDURE
1. Open hood.

2. Disconnect front wheel ABS sensor electrical connector, if applicable.See Figure 1.
3. Route front wheel ABS sensor wiring into wheel well, if applicable.

NOTE:

11. Remove retaining nut and bolt, then separate upper part of stabilizer bar link from steering knuckle.
15. Remove cotter pin and loosen castle nut one (1) or two (2) turns.
16. Remove lack stand supporting lower control arm.
19. Remove lower ball joint stud castle nut.


21. Install Ball Joint Remover D89P-301 0-A, Receiving Cup D84P-3395-A4 and U-Joint Tool T74P-4635-C on low
NOTE:

24.
Install Ball Joint Replacer T8OT-301O-A3, Receiving Cup D84P-3395-A4, U-Joint Tool T74P-4635-C and new
NOTE:
25. Using installed tools and a breaker bar, press ball joint into lower control arm.
29. Install ball joint stud castle nut. Tighten castle nut to 108-162 Nm (80-119 lb-ft). Continue to tighten castle nut un
30. Install new cotter pin in lower ball joint castle nut.
32.
33. Install new Cotter pin in tie-rod castle nut.
34. Install upper part of stabilizer bar link into steering knuckle. Tighten retaining nut to 40-55 Nm (30-40 lb4t).
38. Route the front wheel ABS sensor wiring into engine compartment, if applicable.
40. Lower vehicle.
41. Connect front wheel ABS sensor electrical connector, if applicable.







Supplement # 2 - Attachment II - Labor and Parts Information

LABOR ALLOWANCES
-- Order Processing Center DOESII
> Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid
Ball Joint: SpecificationsFront Suspension Balljoint Inspection Job Aid
Front Lower Balljoint
Between lower control arm and knuckleMeasurement ................................................................................................
0-0.012 in (0-0.3mm)Deflection ......................................................................................................................................
B - but a jackstand must be placed under the lower control arm to "load the suspension".Reference Diagram ..
Front Upper Balljoint
Between upper control arm and knuckleMeasurement ...............................................................................................
0-0.008 in (0-0.2mm)Deflection ......................................................................................................................................

> Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 6892

C - but a jackstand must be placed under the lower control arm to "load the suspension".Reference Diagram ..
Ball Joint: SpecificationsBall Joint, Lower

GENERAL
Radial Play, Max. .............................................................................................................................................................
Retaining Nut (To Spindle) ..............................................................................................................................................
Ball Joint: SpecificationsBall Joint, Upper

GENERAL
Radial Play, Max. .............................................................................................................................................................
Retaining Bolts
To Upper Arm ............................................................................................................................................................

> Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Balljoint Inspection Job Aid
Ball Joint: Testing and InspectionFront Suspension Balljoint Inspection Job Aid
Front Lower Balljoint
Between lower control arm and knuckleMeasurement ................................................................................................
0-0.012 in (0-0.3mm)Deflection ......................................................................................................................................
B - but a jackstand must be placed under the lower control arm to "load the suspension".Reference Diagram ..
Front Upper Balljoint
Between upper control arm and knuckleMeasurement ...............................................................................................
0-0.008 in (0-0.2mm)Deflection ......................................................................................................................................

> Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Balljoint Inspection Job Aid > Page 6897

C - but a jackstand must be placed under the lower control arm to "load the suspension".Reference Diagram ..
Ball Joint: Testing and InspectionBall Joint, Lower
Checking Upper Ball Joint For Wear
1. Support the vehicle in normal driving position with both ball joints loaded.2. Have an assistant grasp the lower edg
wheel spindle and the front suspension lower arm indicates abnormal wear.
4. If any such movement is observed, replace front suspension lower arm.
Ball Joint: Testing and InspectionBall Joint, Upper
Checking Upper Ball Joint For Wear
1. Raise vehicle and place floor jacks beneath the front suspension lower arms.2. Have an assistant grasp the lower e
upper end of the front wheel spindle and the front suspension arm bushing joint indicates abnormal ball joint wea
4. If any such movement is observed, install new front suspension upper ball joint.
> Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower
Ball Joint: Service and RepairBall Joint, Lower

REMOVAL
1. Raise vehicle on hoist.2. Remove front wheel spindle.3. Remove and discard joint boot seal.
4. Press out front suspension arm bushing joint using U-Joint Tool T74P-4635-C, Ball Joint Remover D89P-3010-A
Cup D84P-3395-A4 or equivalent.
INSTALLATION
1. Install front suspension arm bushing joint with Ball Joint Replacer D89P-3010-B or equivalent, Receiving Cup an
NOTE:
When installing a new front suspension arm bushing joint, the protective cover must be left in place during insta
2. Discard the protective cover and check the front suspension lower arm ball joint to make sure it is fully seated in t
and ball joint seal is free of cuts or tears.
3. Install front wheel spindle.4. Check wheel alignment.
> Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower > Page 6902
Ball Joint: Service and RepairBall Joint, Upper
REMOVAL
INSTALLATION
1. Position ball joint assembly on front suspension upper arm and insert ball stud into front wheel spindle.
NOTE: Upper front suspension upper ball joint can be used on either side of vehicle.
76-104 Nm (56-76 ft. lbs.).

145-175 Nm (107-129 ft.2. Install pinch bolt and retaining nut. Tighten to 3. Install alignment cams to the approxima
lbs.).
5. Remove floor jack from front suspension lower arm.6. Install tire and wheel assembly.7. Remove safety stands an
1. Raise the front of the vehicle and position safety stands under the frame behind front suspension lower arm.2. Rem
> Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign - Rear Upper C
Campaign - Rear Upper Control Arm Reinforcement
00B60Owner Notification Program
All 1998 through 2000 Model Year Crown Victoria Police Interceptor, Taxi Cab, Natural Gas Vehicles (NGV), and Lin
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIII^
^ Owner Letter
> Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 00B60 > Feb > 01 > Campaign
- Rear Upper Control Arm Reinforcement > Page 6911


OASIS
PROMPTLY CORRECT
Promptly correct all affected vehicles on the enclosed list and other eligible vehicles brought to your dealership. Immed

OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date o
RENTAL CARS

Attachment II - Parts and Labor Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
DOR/COR NUMBER
DEALER PRICE
For latest prices, refer to
^ DOES II
EXCESS STOCK RETURN

SEVERE DUTY REAR FRAME REPAIR
AFFECTED VEHICLES:1998 AND 2000 CROWN VICTORIA (POLICE, TAXI, NGV), TOWN CAR (LIMOUSINE
OVERVIEW
This procedure is for repairing cracks and installing reinforcement brackets on the rear control arm mounts. Depending
INSPECTION
NOTE:
All illustrations show the right side, the left side is similar.

1. Record radio stations.
NOTE:
Upon reassembly, the control arms must be tightened with the vehicle suspension at ride height. Therefore, the shoc
3. While parked on a level surface, mark the rear suspension shock absorbers relative to the position of their protect
4. Raise the vehicle on a hoist and remove the rear wheels.
NOTE:
Inspect both sides of the vehicle.
5.
Clean and inspect the areas of the upper and lower control arm mounts for cracks as indicated in the illustration. M
A.
If any of the control arm mounts have separated from the frame rail, do not continue with this procedure. C
B.
If no cracks are located, install reinforcement brackets on ALL control arm mounts. Perform REINFORCE
C. Vehicles with only cracks of less than one-half inch in length, proceed as follows.
^
Perform CRACK REPAIR AND COACH WELD PLACEMENT, repairing all cracks and strategically
^ Perform REINFORCEMENT BRACKET INSTALLATION, installing reinforcement brackets on ALL
D. Vehicles with any cracks 1/2 inch long or greater, proceed as follows.
^
Perform CRACK REPAIR AND COACH WELD PLACEMENT, repairing all cracks and placing coac

CRACK REPAIR AND COACH WELD PLACEMENT
NOTE:
Removal of control arm(s) (steps 3 or 4) is not necessary for mounts that do not require coach welds.
1. Position safety stands under the rear axle housing.
2. If equipped with an air spring, wrap the air spring in a protective welding blanket.
3.
Loosen the rear pivot bolt on the lower control arm, then remove the front pivot bolt. Rotate the lower control arm
4. Remove the upper control arm pivot bolts, then remove the upper control arm.
CAUTION
Grind only enough metal away to form the V-groove. Do not grind completely through the frame rail or mount pare

5.
Grind a V-groove in all cracks, then remove the E-coat from around the cracks. Mig weld the groove, using stand

6.
Remove the E-coat from the frame rail(s) and control arm mounts(s) at the coach weld positions as indicated in th
7.
Place one (1) inch coach welds onto the frame rail(s)/control arm mount(s) (starting at the edge of the mount) as i
REINFORCEMENT BRACKET INSTALLATION
NOTE:
If equipped with an air spring, wrap the air spring in a protective welding blanket (if not previously installed during
NOTE:
Reinforcement brackets MAY be welded onto mounts without removal of control arms.
CAUTION
Burn-through is not permitted. If any burn-through occurs, the hole must be filled.
CAUTION
Do not weld on the bends of the brackets.
CAUTION
Only remove E-coat and any weld material that interferes with reinforcement bracket fit. Do not grind frame parent

1.
Prep the frame rail/upper control arm mount by removing the E-coat in the reinforcement bracket mounting area.
2.
Position the upper control arm mount reinforcement bracket with the slotted hole closest to the frame rail. The br
3.
Tack weld the upper control arm mount reinforcement bracket into place. Remove the clamp(s). Then finish weld

4. Prep the frame rail/lower control arm mount by removing the E-coat in the reinforcement bracket mounting area.
5.
Position the lower control arm mount reinforcement bracket. The bracket must fit flush to the frame rail and flush
6.
Tack weld the lower control arm mount reinforcement bracket to the frame rail. Then clamp and tack weld the br
FINAL ASSEMBLY
1. Remove weld blankets, if previously installed.
2. Install all of the control arms and/or flag nut(s) that were removed. Do not final tighten at this time.
3. Remove the safety stands.
WARNING
RIDE HEIGHT MUST BE ACHIEVED BY SUPPORTING THE REAR AXLE WITH SHORT SAFETY STAND

4.
Position two (2) short safety stands directly under the rear axle housing. Lower the hoist so the rear axle is suppo
5. Verify the rear shock absorber ride height reference marks are in alignment.
NOTE:
Tighten all of the control arms that were removed.
6.
Tighten both lower control arm pivot bolts and the upper control arm to frame mount pivot bolt to 150 Nm (111 l
7. Raise the vehicle on a hoist, then remove the safety stands.
8. Spray undercoating on reinforcement brackets, welds and all bare metal (avoid excessive overspray).
9. Install the rear wheels. Tighten the lug nuts to 129 Nm (95 lb-ft).
10. Lower the vehicle, then connect the battery ground cable.
11. Program the radio stations.



> Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60 > Feb > 01 > C
Reinforcement
Campaign - Rear Upper Control Arm Reinforcement
00B60Owner Notification Program
All 1998 through 2000 Model Year Crown Victoria Police Interceptor, Taxi Cab, Natural Gas Vehicles (NGV), and Lin
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIII^
^ Owner Letter
> Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 00B60
> Feb > 01 > Campaign - Rear Upper Control Arm Reinforcement > Page 6928


OASIS
PROMPTLY CORRECT
Promptly correct all affected vehicles on the enclosed list and other eligible vehicles brought to your dealership. Immed

OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date o
RENTAL CARS

Attachment II - Parts and Labor Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
DOR/COR NUMBER
DEALER PRICE
For latest prices, refer to
^ DOES II
EXCESS STOCK RETURN

SEVERE DUTY REAR FRAME REPAIR
AFFECTED VEHICLES:1998 AND 2000 CROWN VICTORIA (POLICE, TAXI, NGV), TOWN CAR (LIMOUSINE
OVERVIEW
This procedure is for repairing cracks and installing reinforcement brackets on the rear control arm mounts. Depending
INSPECTION
NOTE:
All illustrations show the right side, the left side is similar.

NOTE:
Upon reassembly, the control arms must be tightened with the vehicle suspension at ride height. Therefore, the shoc
3. While parked on a level surface, mark the rear suspension shock absorbers relative to the position of their protect
4. Raise the vehicle on a hoist and remove the rear wheels.
NOTE:
Inspect both sides of the vehicle.
5.
Clean and inspect the areas of the upper and lower control arm mounts for cracks as indicated in the illustration. M
A.
If any of the control arm mounts have separated from the frame rail, do not continue with this procedure. C
B.
If no cracks are located, install reinforcement brackets on ALL control arm mounts. Perform REINFORCE
C. Vehicles with only cracks of less than one-half inch in length, proceed as follows.
^
Perform CRACK REPAIR AND COACH WELD PLACEMENT, repairing all cracks and strategically
D. Vehicles with any cracks 1/2 inch long or greater, proceed as follows.
^
Perform CRACK REPAIR AND COACH WELD PLACEMENT, repairing all cracks and placing coac

CRACK REPAIR AND COACH WELD PLACEMENT
NOTE:
Removal of control arm(s) (steps 3 or 4) is not necessary for mounts that do not require coach welds.
1. Position safety stands under the rear axle housing.
2. If equipped with an air spring, wrap the air spring in a protective welding blanket.
3.
Loosen the rear pivot bolt on the lower control arm, then remove the front pivot bolt. Rotate the lower control arm
4. Remove the upper control arm pivot bolts, then remove the upper control arm.
CAUTION
Grind only enough metal away to form the V-groove. Do not grind completely through the frame rail or mount pare

5.
Grind a V-groove in all cracks, then remove the E-coat from around the cracks. Mig weld the groove, using stand

6.
Remove the E-coat from the frame rail(s) and control arm mounts(s) at the coach weld positions as indicated in th
7.
Place one (1) inch coach welds onto the frame rail(s)/control arm mount(s) (starting at the edge of the mount) as i
REINFORCEMENT BRACKET INSTALLATION
NOTE:
If equipped with an air spring, wrap the air spring in a protective welding blanket (if not previously installed during
NOTE:
Reinforcement brackets MAY be welded onto mounts without removal of control arms.
CAUTION
Burn-through is not permitted. If any burn-through occurs, the hole must be filled.
CAUTION
Do not weld on the bends of the brackets.
CAUTION
Only remove E-coat and any weld material that interferes with reinforcement bracket fit. Do not grind frame parent

1.
Prep the frame rail/upper control arm mount by removing the E-coat in the reinforcement bracket mounting area.
2.
Position the upper control arm mount reinforcement bracket with the slotted hole closest to the frame rail. The br
3.
Tack weld the upper control arm mount reinforcement bracket into place. Remove the clamp(s). Then finish weld

4. Prep the frame rail/lower control arm mount by removing the E-coat in the reinforcement bracket mounting area.
5.
Position the lower control arm mount reinforcement bracket. The bracket must fit flush to the frame rail and flush
6.
Tack weld the lower control arm mount reinforcement bracket to the frame rail. Then clamp and tack weld the br
FINAL ASSEMBLY
2. Install all of the control arms and/or flag nut(s) that were removed. Do not final tighten at this time.
3. Remove the safety stands.
WARNING
RIDE HEIGHT MUST BE ACHIEVED BY SUPPORTING THE REAR AXLE WITH SHORT SAFETY STAND

4.
Position two (2) short safety stands directly under the rear axle housing. Lower the hoist so the rear axle is suppo
5. Verify the rear shock absorber ride height reference marks are in alignment.
NOTE:
Tighten all of the control arms that were removed.
6.
Tighten both lower control arm pivot bolts and the upper control arm to frame mount pivot bolt to 150 Nm (111 l
7. Raise the vehicle on a hoist, then remove the safety stands.
8. Spray undercoating on reinforcement brackets, welds and all bare metal (avoid excessive overspray).
9. Install the rear wheels. Tighten the lug nuts to 129 Nm (95 lb-ft).
10. Lower the vehicle, then connect the battery ground cable.
11. Program the radio stations.



> Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Page 6940
Control Arm: Specifications

RETAINING BOLTS/NUTS
Front
Lower Arm-to-Frame..................................................................................................................................................
Rear
Lower Arm-to-Axle ....................................................................................................................................................

> Steering and Suspension > Suspension > Control Arm > Component Information > Testing and Inspection > Bushing Inspection
Control Arm: Testing and InspectionBushing Inspection

-
Check all front and rear suspension rubber bushings for wear or deterioration while supporting the vehicle and th
-
Test all rubber-bushed suspension mounting and connecting points for free play in the unloaded condition. Use a
> Steering and Suspension > Suspension > Control Arm > Component Information > Testing and Inspection > Bushing Inspection > Page 6943
Control Arm: Testing and InspectionDamage Inspection
Check for signs of damage and possible deformation due to curb impacts, improper hoisting, etc. If any such damage is
> Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front
Control Arm: Service and RepairFront
Lower
REMOVAL
1. Raise the front of the vehicle arid position safety stands under both sides of the frame just behind the front suspens
wheel and tire.
2. Remove disc brake caliper, front disc brake rotor and front brake anti-lock sensor if equipped. Discard disc brake c
Brakes and Traction Control.
3. Remove the front suspension bumper inspect and save for installation if in good condition.4. Remove front shock
Part 1 Of 2
6. Loosen the lower ball joint stud nut one or two turns.
WARNING: TO PREVENT INJURY, DO NOT REMOVE THE NUT FROM THE BALL JOINT STUD
7. Tap the front wheel spindle sharply, near the lower stud, with a hammer to loosen the stud in the front wheel spind
10. Remove the ball joint nut and remove front suspension lower arm assembly.11. Remove fasteners at frame bracke
INSTALLATION
1. Position front suspension lower arm in frame brackets and loosely assemble fasteners.2. Position the front suspens
148-201 Nm (110-148 ft. lbs.).
NOTE:
Make sure that the pigtail of the lower coil of the front coil spring is in the proper location of the front spring ins
3. Position the front coil spring into the upper spring pocket and raise the front suspension lower arm, aligning the ho
the crossmember. Install bolts and nuts with washer installed on the front bushing. Do not tighten at this time.
> Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 6946

47-63 Nm (35-46 ft.4. Remove the coil spring compressor.5. Connect the steering sector shaft arm drag link at the st
lbs.). Continue to tighten until slot for cotter pin is aligned. Install a new cotter pin.
148-201 Nm (110-148 ft. lbs.). 6. Install front shock absorber.7. Install the front suspension bumper. Tighten front su
mounting bolts. See Brakes and Traction Control.
9. Install wheel and tire and lower vehicle.
148-20110. With the vehicle supported on the wheels and tires at normal curb height, tighten the front suspension low
Nm (110-148 ft. lbs.).
11. Check caster, camber and toe. Adjust as required.
Upper
REMOVAL
1. Raise the front of the vehicle and position safety stands under both sides of the frame just behind front suspension
INSTALLATION
148-201 Nm (110-148 ft. lbs.). 76-104 Nm (56-76 ft.1. Use reference marks from camber and caster cams as initial
lbs.).
4. Install the wheel and tire.5. Remove safety stands and lower front of vehicle.6. Check caster, camber and toe. Adju
Control Arm: Service and RepairRear
Lower
REMOVAL
CAUTION:
The rear suspension fasteners are important parts because they effect performance of vital components and syste
2. Mark the rear suspension shock absorber relative to the protective sleeve with the vehicle in a static, level ground

5. Use Hi-Lift Jack 014-00942 or equivalent to support the rear axle.6. If equipped, release the air pressure from the
WARNING: DO NOT REMOVE AN AIR SPRING UNDER ANY CIRCUMSTANCES WHEN THERE I
7. Remove and discard the rear suspension lower arm pivot bolt and nut from the axle bracket.
NOTE: If both rear suspension upper arms and both rear suspension lower arms are to be replaced at the same ti
8. Remove and discard the rear suspension lower arm pivot bolt and nut from the frame bracket. Remove the rear sus
INSTALLATION
1. Position the rear suspension lower arm to the frame bracket and install a new pivot bolt and nut. Insert the bolt so
tighten at this time.
NOTE:
- The rear suspension lower arm bolts must be tightened with the vehicle at curb height.
-
The rear suspension lower arms are interchangeable from side-to-side with "OUTBOARD" stamped on th
2. Position the rear suspension lower arm to the axle bracket and install a new pivot bolt and nut. Insert the bolt so th
128-172 Nm (95-127 ft. lbs.).

128-172 Nm (95-127 ft. lbs.).
3. Raise the axle assembly to the position that compresses the shock absorber to the previously established alignment
Upper

REMOVAL
CAUTION:

AIR SPRING. DO NOT REMOVE ANY COMPONENTS SUPPORTING AN AIR SPRING WITHOUT EXHA
6. Remove and discard the rear suspension upper arm pivot and nut from the axle bracket.
CAUTION:
Do not use excessive force when removing the pivot bolt and flag nut on the right upper suspension arm to axle
NOTE: If both rear suspension upper arms and both rear suspension lower arms are to be replaced at the same ti
6. Remove and discard the rear suspension upper arm pivot bolt and nut from the frame bracket and remove the rear
INSTALLATION
1. Position the rear suspension upper arm to the frame bracket and install a new pivot bolt and nut. Insert the bolt so
NOTE: The rear suspension upper arm bolts must be tightened with the vehicle at curb height.
2. Position the rear suspension upper arm to the axle bracket and install a new pivot bolt and nut. Insert the bolt so th
128-172 Nm (95-127 ft. lbs.).

88-118 Nm (65-88 ft. lbs.).
3. Raise the axle assembly to the position that compresses the shock absorber to the previously established alignment
> Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications
Lateral Stabilizer Rod: Specifications

NOTE: The rear suspension lateral arm pivot bolts and the Watts link pivot nut must be tightened with the vehicle at c
Watts Link
Pivot Stud .........................................................................................................................................................................

Lateral Arm
Arms To Watts Link .........................................................................................................................................................

> Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications > Page 6954
Lateral & Watts Link

> Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications > Page 6955

> Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Disassembly and Assembly
Lateral Stabilizer Rod: Service and RepairDisassembly and Assembly
DISASSEMBLY
1. Remove the lateral arm and Watts link pivot assembly.
NOTE: The lateral arms and the Watts link pivot assembly can be serviced separately or as a complete assembly
2. Mark the position of the lateral arms on the Watts link pivot for positioning during installation.
Height Sensor
3. Mark the position of the height sensor mounting bracket to the lateral arm for positioning during installation.4. Re
> Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Disassembly and Assembly > Page 6958

ASSEMBLY
80-104 Nm (60-77 ft. lbs.). 12-15 Nm (9-12 ft. lbs.).1. Follow the removal procedure in reverse order.2. Tighten the
Lateral Stabilizer Rod: Service and RepairReplacement

REMOVAL
CAUTION:
NOTE: If the Watts link pivot stud or nut is loosened, a new Watts link pivot stud and nut service kit must be in

6. Disconnect the height sensor from the mounting bracket.7. Remove and discard both lateral arm assembly pivot bo
NOTE: -
The Watts link pivot stud is coated with a dry adhesive and must be replaced whenever the pivot nut or stud is
-
If the Watts link pivot stud on the axle assembly loosens while removing the pivot nut, continue to loosen the
9. Lower the axle until the Watts link is free of the pivot stud and remove the lateral arm assembly.
10. Remove and discard the Watts link pivot stud.
INSTALLATION
255-285 Nm (189-211 ft. lbs.). 212-287 Nm1. Install a new Watts link pivot stud to the axle assembly and tighten to
(158-212 ft. lbs.).
NOTE:
- The rear suspension lateral arm pivot bolts and the Watts link pivot nut must be tightened with the vehicle
- The right lateral arm goes under the exhaust pipe and the left lateral arm goes over the exhaust pipe.
3. Raise the axle until the lateral arm assembly aligns with the frame brackets and install new pivot bolts and nuts. D

88-118 Nm (65-88 ft. lbs.).4. Raise the axle assembly to the position that compresses the shock absorber to the previ
6. Connect the height sensor to the mounting bracket.7. Remove Hi-Lift Jack 014-00942 or equivalent.8. Lower the v
> Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Compressor Relay (Le

Engine View
> Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Compressor Relay (Le

> Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 6968
> Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 6969
REMOVAL
INSTALLATION
> Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations

> Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 6973


DESCRIPTION
OPERATION
-
-
-
-
-
REMOVAL
INSTALLATION
> Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications

> Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Specifications > Page 6981

DESCRIPTION
OPERATION
suspension frame
height crossmember
oneoperates
end andas
at follows:-
-
REMOVAL
INSTALLATION
> Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Specifications

> Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Specifications > Page 6987

> Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Specifications > Page 6988
An 30 rpmshock
- 60 rpm
- 30 rpm,
> Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Sensor
REMOVAL
INSTALLATION
> Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Sensor > Page 6991
REMOVAL
INSTALLATION
> Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Locations
> Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Locations > Page 6995
NOTE:
> Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Locations > Page 6996

REMOVAL
INSTALLATION
> Steering and Suspension > Suspension > Sensors and Switches - Suspension > Vehicle Speed Sensor Signal > Component Information > Specifications

Retaining Bolt ......................................................................................................................................................................
> Steering and Suspension > Suspension > Sensors and Switches - Suspension > Vehicle Speed Sensor Signal > Component Information > Specifications > Page 7000
(VSS) (EVO)
TheThe output
vehicle current
speed to the
electronic whe
variable
- 600 mA. 600 mA
> Steering and Suspension > Suspension > Sensors and Switches - Suspension > Vehicle Speed Sensor Signal > Component Information > Specifications > Page 7001
REMOVAL
(VSS)
INSTALLATION
> Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair
Spindle: Service and Repair

REMOVAL
1. Raise the front of the vehicle and position safety stands under both sides of the frame just behind the front suspens
4. Disconnect the tie rod end from the front wheel spindle using Tie Rod End Remover TOOL-3290-D or equivalent
stabilizer bar link from the front wheel spindle. Remove and discard nut.
8. Remove pinch bolt from upper ball joint and stabilizer ball link joint at front wheel spindle.9. Position a floor jack
10. Remove the lower ball joint stud nut. Remove the front wheel spindle. Pry the slot with a suitable pry bar at the up
front wheel spindle.
INSTALLATION
1. Position front wheel spindle on upper ball joint stud. Install pinch bolt and loosely install nut.2. Position front whe
26-35 Nm (20-25 ft. lbs.).Tighten to
NOTE: Skirt can be removed from nut provided sufficient load of 889 N (200 lbs.) can be generated between ba
148-201 Nm (110-148 ft.3. Position the front wheel spindle on the lower ball joint stud and install a new skirted nylo
lbs.).
Raise the front suspension lower arm and guide the upper ball joint stud into the front wheel spindle. Install the p
76-104 Nm (56-76 ft. lbs.)

47-63 Nm (35-46 ft. lbs.).4. Tighten the upper ball joint pinch bolt nut to and remove floor jack.5. Connect the tie ro
pin is aligned. Install a new cotter pin.
6. Install the front disc brake rotor shield, front disc brake rotor, disc brake caliper and front brake anti-lock sensor if
7. Install the wheel and tire assembly.8. Remove the safety stands and lower the vehicle.9. Check caster, camber and
> Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Testing and Inspection
Stabilizer Bushing: Testing and Inspection

-
Check all front and rear suspension rubber bushings for wear or deterioration while supporting the vehicle and th
-
Test all rubber-bushed suspension mounting and connecting points for free play in the unloaded condition. Use a
> Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Testing and Inspection > Page 7009
Stabilizer Bushing: Service and Repair
REMOVAL
1. Raise vehicle on hoist.2. Remove four stabilizer bar bracket nuts and two stabilizer bar brackets.3. Remove lower
INSTALLATION
26-35 Nm (19-26 ft. lbs.).1. Clean front stabilizer bar of dirt and other contaminations.2. Position lower suspension a
> Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications
Stabilizer Link: Specifications

Retaining Nuts
Front
To Spindle .............................................................................................................................................................
Rear ............................................................................................................................................................................
> Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications > Page 7013
> Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications > Page 7014
Stabilizer Link: Service and Repair
REMOVAL
1. Raise the vehicle on hoist.2. Remove retaining nuts from stabilizer bar links at front stabilizer bar.3. Loosen front
from front wheel spindle. Remove and discard nut.
4. Remove stabilizer bar links from front stabilizer bar.
INSTALLATION
26-35 Nm (20-25 ft. lbs.).

26-35 Nm (20-25 ft. lbs.). 1. Position stabilizer bar links into end of front stabilizer bar with retaining nuts. Do not ti
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Specifications
Air Dryer: Specifications

Retaining Bolts ....................................................................................................................................................................
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Specifications > Page 7019
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Specifications > Page 7020
Air Dryer: Service and Repair
REMOVAL
2. Remove air compressor and compressor air drier assembly.3. Remove compressor air drier-to-compressor retainin
5. Remove compressor air drier and O-ring seal. Discard O-ring seal.
INSTALLATION
1.6-2.8 Nm (15-24 inch lbs.).

1. Install new O-ring on compressor air drier to make sure it is properly seated on compressor air drier end.2. Install
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Locations
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Description and Operation > Air Line J
Air Line: Description and OperationAir Line Joint

- Air lines are replaceable. However, quick-connect unions and bulk tubing are available to mend a damaged ai
- Collet and O-ring of the quick-connect fitting is replaceable.
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Description and Operation > Air Line J
Air Line: Description and OperationAir Line (Level Control)

- Air lines are replaceable. However, quick-connect unions and bulk tubing are available to mend a damaged ai
- Collet and O-ring of the quick-connect fitting is replaceable.
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Service and Repair > Air Line Joint
Air Line: Service and RepairAir Line Joint
DESCRIPTION
If aAir
leakcompressor
is detected to
in drier:
any ofone
theO-ring.
quick connect fittings, it can be serviced using a service kit containing a new O-
- Air spring solenoid to end cap: two O-rings each air spring solenoid.
- Quick connect fitting: two O-rings at compressor air drier, one O-ring at each spring and junction block.
If air leaks are detected in these areas, remove components and install new O-rings.
PROCEDURE
1. To remove the collet and O-ring, insert a scrap piece of air line, grasp the air line firmly (do not use pliers) and pu
130-220 N (30-50 lbs)release button. A force of is required to remove the collet.
2. After the collet is removed, use the removal tool to remove the old O-ring.3. To service, first make sure the seal ar
release button.
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Service and Repair > Air Line Joint > P
Air Line: Service and RepairAir Line (Level Control)
NOTE: With the air compressor ON, a soap and water solution applied to air lines will locate air leaks.
If a leak is detected in an air line, it can be serviced as follows:1. First, carefully cut the line with a sharp knife for a g
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Locations
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Locations > Page 7033
Air Spring: Service Precautions
WARNING:
-
DO NOT ATTEMPT TO INSTALL OR INFLATE ANY REAR AIR SPRING THAT HAS BECOME UN
-
FAILURE TO OBSERVE THE FOLLOWING PROCEDURES MAY RESULT IN A SUDDEN FAILURE
- ANY REAR SPRING WHICH IS UNFOLDED MUST BE REFOLDED AS SHOWN, PRIOR TO BEING
-
THE AIR SPRING REFOLDING PROCEDURE SHOULD ONLY BE USED TO FOR AN AIR SPRING
-
IMPROPERLY FOLDED AIR SPRINGS FOUND ON VEHICLES DURING PRE-DELIVERY INSPECT
-
DO NOT ATTEMPT TO INFLATE ANY AIR SPRING WHICH HAS BEEN COLLAPSED WHILE UNI
-
WHEN INSTALLING A NEW AIR SPRING, CARE MUST BE TAKEN NOT TO APPLY A LOAD TO T
- AFTER INFLATING AN AIR SPRING IN HANGING POSITION, IT MUST BE INSPECTED FOR PRO
-
POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF BY TURNING THE AIR SUSPE
-
THE ELECTRICAL POWER SUPPLY TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PR
-
DO NOT REMOVE AN AIR SPRING UNDER ANY CIRCUMSTANCES WHEN THERE IS PRESSURE
CAUTION:
Replacement Fasteners
Suspension
Fastener fasteners are IMPORTANT attaching parts in that they could affect performance of vital compone
Tightening/Torque
Specified torque values must be used during assembly for proper retention of parts. New fasteners must be us
Bending/Heating
Never attempt to heat, quench or straighten any suspension part. Replace with a new part.
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Locations > Page 7034
Air Spring: Description and Operation
Air Spring
Tworeplace the conventional coil springs.

rear springs:-
- support the vehicle load at the rear wheels.
- are mounted between the axle spring seats and the frame upper spring seats, similar to the conventional rear coil s
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Spring Filling or Refolding
Air Spring: Service and RepairAir Spring Filling or Refolding
WARNING: WHEN INSTALLING DEFLATED REAR SPRING ON THE VEHICLE, LOWER THE HOIST
1. Support frame so rear wheels are off ground with no load applied to rear suspension.2. Air suspension switch mus
connector.
5. Set Super Star II tester to EEC-IV/MCU mode. Also set Super Star II tester to FAST mode. Release Star tester but
turn tester ON.
6. Press Star Tester button to TEST (down) position. A DTC 10 will be displayed. Within two minutes a DTC 13 wil
displayed, release tester button to HOLD (up) position, wait two seconds and press tester button to TEST (down)
7. Release tester button to the HOLD (up) position. Wait at least 20 seconds, then press tester button to the TEST (do
seconds, the following DTCs will start to be displayed in the order shown:
DTC Description
23 Vent Rear26 Compress Rear31 Cycle Compressor On and Off Repeatedly32 Cycle Vent Solenoid
8. Within four seconds after DTC 26 is displayed, release tester button to the HOLD (up) position. (Waiting longer th
Functional Test 31 being entered.) The air compressor will fill the air springs with air as long as the test button is
NOTE:
It is possible to overheat the air compressor during this operation. If the air compressor overheats, the self-resett
9. To exit Functional Test DTC 26, disconnect the Star tester and turn the ignition switch OFF.
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Spring Filling or Refolding > Pa
Air Spring: Service and RepairPiston Retainer Clip
CAUTION:
Retainer clip may be distorted. Visually inspect for bent fingers at outer diameter of clip or distortion across retainer c
REMOVAL
1. Using needle nose pliers, bend each of four prongs (holding rear air spring retainer to piston knob) outward.2. Rem
INSTALLATION
1. Align new rear air spring retainer over piston knob.
CAUTION: Do not clamp any portion of the rear spring piston to prevent damage to vehicle.
2. Position a 1-inch diameter socket on rear air spring retainer and push clip downward until clip is fully seated on pi
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Spring Filling or Refolding > Pa
Air Spring: Service and RepairReplacement
NOTE:Vehicles equipped with coil springs are serviced similarly to vehicles with air springs. The procedure for air sp
REMOVAL
1. Turn air suspension switch OFF.2. Raise vehicle on a hoist. Suspension must be fully down with no load.3. Remov
5. Remove air spring solenoid valve.
Removing Air Spring

6. Remove spring piston-to-axle spring seat.
a. Insert Air Spring Remover T90P-5310-A between axle tube and spring seat on forward side of axle.b. Position
7. Remove rear spring.8. Inspect air spring piston retainer clip. See: Piston Retainer Clip
INSTALLATION
1. Install rear spring solenoid valve.2. Install rear spring into frame spring seat, taking care to keep solenoid valve air
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Spring Filling or
Refolding > Page 7039

5. Install heat shield to frame rear spring seat, if required.6. Align air rear spring piston to axle seats. Squeeze to incr
supported by shock absorber.
CAUTION: Air rear springs may be damaged if suspension is allowed to compress before spring is inflated.
7. Refill air rear springs.

> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Specifications
Compressor/Pump: Specifications
Retaining Bolts ....................................................................................................................................................................
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Specifications > Page 7043
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Specifications > Page 7044
Compressor/Pump: Description and Operation

NOTE:
- The compressor motor contains a thermal overload circuit breaker. The circuit breaker automatically resets if trip
- The compressor air drier may be serviced separately.
DESCRIPTION
Theconsists of the compressor

air compressor assembly:-and vent solenoid; neither is serviceable.
- (ACL).is mounted in the engine compartment on the LH fender apron below the engine air cleaner
- is a single-cylinder electric motor-driven unit which provides pressurized air as required.
- is powered by a relay, controlled by the control module.
- passes pressurized air through the compressor air drier which contains silica gel (a drying agent).
- moisture is then removed from the compressor air drier when vented air passes out of the system during vent ope
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Service and Repair > Air Com
Compressor/Pump: Service and RepairAir Compressor

REMOVAL
(ACL).
1. Disconnect battery ground cable. 2. Remove engine air cleaner See Powertrain Management.3. Remove windshie
4. Remove compressor wheel hub splash shield and push pins.5. Remove air line from compressor air drier by pushin
6. Disconnect compressor electrical connector.7. If necessary, raise vehicle on hoist.

> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Service and
Repair > Air Compressor > Page 7047

8. Remove three nuts retaining air compressor to fender apron.9. Lower vehicle.
10. Remove air compressor and compressor air drier assembly.
INSTALLATION
5.4-8.1 Nm (48-71 inch lbs.).1. Follow removal procedure in reverse order.2. Tighten compressor to fender retaining
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Service and Repair > Air Com
Compressor/Pump: Service and RepairCompressor Mounting Bracket

REMOVAL
1. Turn air suspension service switch OFF.2. Remove air compressor and compressor air drier assembly.3. Remove t
INSTALLATION
1. Position mounting bracket to body side apron with two locating tabs. 2. Secure three nuts retaining bracket to body
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Compress

Engine View
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Compress

> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 7054
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 7055
REMOVAL
INSTALLATION
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Diagnostic Connector, Suspension > Component Information > Locations

Full Body View
The Air Suspension Test Connector is located at the RH side of the trunk.
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Diagnostic Connector, Suspension > Component Information > Locations > Page 7059
Air Suspension Test Connector

> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Description and Operation > Electroni
Level Control Solenoid Valve: Description and OperationElectronic Level Control Solenoid Valve
WARNING: NEVER ROTATE AN AIR SPRING SOLENOID VALVE TO THE RELEASE SLOT IN THE EN
- The air spring solenoid valve allows air to enter and exit the air spring during leveling corrections.
- The valve is electrically operated and controlled by the control module.
- The valve has a two-stage pressure relief system similar to a radiator pressure cap.
- An air spring solenoid retainer is first removed.
- (NGS)
Use the active command modes on Rotunda New Generation Star Tester 007-00500 or equivalent to vent the
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Description and Operation > Electroni
Page 7064
Level Control Solenoid Valve: Description and OperationVent Solenoid (Level Control)
CAUTION:
The vent solenoid valve has an internal diode for electrical noise suppression and therefore is polarity sensitive. Care
Theallows air to escape

vent solenoid from the system during venting corrections.
valve:-
- is located above the air compressor cylinder head.
- is attached to the cylinder head casting, which forms an integral valve housing that allows the valve tip to enter th
- has an O-ring seal which prevents air leakage past the valve tip.
- opens when the rear is high and the control module determines lowering is required.
- provides an escape route for pressurized air when opened.
- the vehicle will not lower unless the air spring solenoid valves are also opened to allow air to leave the rear sprin
- air is exhausted from the springs and vented through the compressor air drier.
- is not a repairable item.
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Description and Operation > Page 706
Level Control Solenoid Valve: Service and Repair
Air Spring
REMOVAL
NOTE: The air spring solenoid valve has a two-stage solenoid valve pressure relief fitting similar to a radiator cap.
1. Vent rear air springs using Functional Test DTC 23.2. Turn air suspension switch OFF.3. Raise vehicle on a hoist.
5. Disconnect solenoid valve electrical connector and then disconnect air line.6. Remove air spring solenoid retainer.
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Description and
Operation > Page 7066

WARNING: DO NOT FULLY RELEASE SOLENOID VALVE UNTIL AIR IS COMPLETELY BLED F
9. After air is fully bled from system, rotate solenoid valve counterclockwise to third stop and remove solenoid valve
10. Remove large solenoid O-ring from solenoid housing.

> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Description and
Operation > Page 7067

INSTALLATION
1. Check solenoid wrings for abrasion or cuts. Replace solenoid wrings as required. Lightly grease O-ring area of sol
housing solenoid O-ring with Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equi
2. Insert solenoid valve into air spring end cap and rotate clockwise to third stop, push into second stop, then rotate c
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Specifications

> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Specifications > Page 7071

DESCRIPTION
OPERATION
suspension frame
height crossmember
oneoperates
end andas
at follows:-
-
REMOVAL
INSTALLATION
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Locations

> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Locations > Page 7077


DESCRIPTION
OPERATION
-
-
-
-
-
REMOVAL
INSTALLATION
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Locations
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Locations > Page 7084
NOTE:
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Locations > Page 7085

REMOVAL
INSTALLATION
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Vehicle Speed Sensor Signal > Component Information > Specifications

Retaining Bolt ......................................................................................................................................................................
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Vehicle Speed Sensor Signal > Component Information > Specifications > Page 7089
(VSS) (EVO)
TheThe output
vehicle current
speed to the
electronic whe
variable
- 600 mA. 600 mA
> Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Vehicle Speed Sensor Signal > Component Information > Specifications > Page 7090
REMOVAL
(VSS)
INSTALLATION
> Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Locations
> Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Locations > Page 7094
Suspension Spring ( Coil / Leaf ): Description and Operation

- Two rear springs are connected between the rear axle and frame.
- Each rear spring is mounted to an upper seat integral with the frame and a lower seat welded to the rear axle hous
-
Two different types of rear springs, air springs or coil springs are used. These procedures show air springs, vehic
> Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front
Suspension Spring ( Coil / Leaf ): Service and RepairFront

REMOVAL
1. Raise vehicle on a hoist. Remove wheel and tire assembly.2. Remove the two bolts retaining the front shock absor
6. Using Coil Spring Compressor D78P-5310-A or equivalent, install one plate with the pivot ball seat facing downw
coil spring. Rotate the plate so it is flush with the upper surface of the front suspension lower arm.
7. Install the other plate with the pivot ball seat facing upward into the coils of the front coil spring. Insert the upper b
front coil spring so nut rests in the upper plate.
NOTE: This pin can only be inserted one way into the upper ball nut because of a stepped hole design.
> Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 7097

8. Insert the compression rod into the opening in the front suspension lower arm, through the upper and lower plate a
securing pin through the upper ball nut and compression rod.
9. With the upper ball nut secured, turn the upper plate so it walks up the coil until it contacts the upper front spring i
turn.
10. Install the lower ball nut and thrust washer on the compression rod and screw on the forcing nut.

11. Tighten the forcing nut until the front cold spring is compressed enough so it is free in its front spring insulator.12
front coil spring.
13. If a new front coil spring is to be installed:
a. Mark the position of the upper and lower plates on the front coil spring with chalk.b. With an assistant, compre
front coil spring.
14. Loosen the forcing nut to relieve spring tension and remove the tools from the front coil spring.
INSTALLATION

1. Assemble the coil spring compressor and locate in the same position as indicated in Removal, Step 13a.
NOTE: Before compressing the front coil spring make sure the upper ball nut securing pin is inserted properly.
2. Compress front coil spring until spring height reaches the dimension obtained in Removal, Step 13b.3. Position th
NOTE: The tail of the front coil spring must be positioned as shown.
4. To install front coil spring, reverse Removal procedure.
Suspension Spring ( Coil / Leaf ): Service and RepairRear
NOTE:Vehicles equipped with coil springs are serviced similarly to vehicles with air springs. The procedure for air sp
REMOVAL
1. Turn air suspension switch OFF.2. Raise vehicle on a hoist. Suspension must be fully down with no load.3. Remov
5. Remove air spring solenoid valve.
Removing Air Spring

6. Remove spring piston-to-axle spring seat.
a. Insert Air Spring Remover T90P-5310-A between axle tube and spring seat on forward side of axle.b. Position
7. Remove rear spring.8. Inspect air spring piston retainer clip. See: Suspension Control ( Automatic - Electronic )/A
INSTALLATION
1. Install rear spring solenoid valve.2. Install rear spring into frame spring seat, taking care to keep solenoid valve air

5. Install heat shield to frame rear spring seat, if required.6. Align air rear spring piston to axle seats. Squeeze to incr
supported by shock absorber.
CAUTION: Air rear springs may be damaged if suspension is allowed to compress before spring is inflated.
7. Refill air rear springs.

> Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Page 7102
> Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications
Suspension Strut / Shock Absorber: Specifications

MOUNTING BOLTS/NUTS
Front
Upper ..........................................................................................................................................................................
Rear
Upper ..........................................................................................................................................................................
> Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Page 7106
Suspension Strut / Shock Absorber: Description and Operation

DESCRIPTION
These vehicles are equipped with gas-pressurized hydraulic shock absorbers. These shock absorbers are not adjus
FRONT
The front shock absorbers provide motion and force damping between the sprung and unsprung masses of the veh
The front shock absorbers consists of a twin tube gas-pressurized structure providing damping in both the reb
- This damping is accomplished by driving a dual (rebound and compression) acting piston through a fluid envi
- The motion resistant forces are controlled by a velocity sensitive variable orifice piston assembly within the fr
REAR
TheProvide motion
rear shock and force damping of the rear suspension during suspension travel.
absorbers:-
- Consist of a twin tube, gas pressurized structure damping in both rebound (up) and compression (down) direc
> Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Bench Test
Suspension Strut / Shock Absorber: Testing and InspectionBench Test

1. With the shock absorber right side up (as installed in vehicle), extend it fully. Then turn the shock absorber upside
Repeat this procedure at least three times to make sure any trapped air has been expelled. Now place the shock ab
2. Install a new shock absorber if any of the following abnormal conditions are met:
-
If the shock absorber is properly primed in its installed position and there is a lag or a skip occurring near mid
- If there is any seizing during the shaft full travel, except at either end of the travel.
- If upon the shaft fast reverse stroke there is any noise encountered other than a faint swish, such as a clicking
- If there are excessive fluid leaks or the front shock absorber action remains erratic after purging air.
> Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Bench Test > Page 7109
Suspension Strut / Shock Absorber: Testing and InspectionHoist Check

Noise:
Noise can be caused by loose suspension or shock absorber attachments. Verify that all attachments for the suspe
Bottom/Hopping:
Check condition of the rubber suspension travel stops (front shock absorber jounce bumper). Replace if worn or m
Force-Check
Support suspension lower arm or rear axle housing and remove lower shock absorber attachment. Stroke shock a
NOTE:
Replace only the worn or damaged shock absorber. Shock absorbers do not require replacement in pairs, unless bot
> Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Bench Test > Page 7110
Suspension Strut / Shock Absorber: Testing and InspectionOn Vehicle

NOTE:
All vehicles are equipped with low-pressure gas pressurized hydraulic shock absorbers. These shock absorbers are not
1. Oil Leak: A light film of oil (seepage) on the upper portion of the shock absorber is permissible and is a result of p
lubrication. Seepage is a condition in which a thin film of oil may be deposited on the shock absorber outer tube (
2. Vehicle Sag: Many times shock absorbers are replaced in an effort to solve a vehicle sag concern. Shock absorbers
damping units only and unlike suspension springs, do not support any suspension loads. Therefore, replacing a sh
NOTE: Shock absorbers no longer need to be replaced in pairs when only one unit is worn or damaged.
3. Replacement in Pairs: In the past it was recommended that shock absorbers and/or springs be replaced in pairs if o
Improved sealing, due to new technology and improved manufacturing quality checks, have added to the function
> Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber
Suspension Strut / Shock Absorber: Service and RepairFront Air Shock Absorber
WARNING: ALL VEHICLES ARE EQUIPPED WITH GAS-PRESSURIZED FRONT SHOCK ABSORBERS
REMOVAL
1. Remove upper shock absorber nut.2. Raise the vehicle on a hoist.3. Remove the two screws attaching the front sho
brush, lightly brush the shock studs to remove rust, oil or corrosion.
4. Remove front shock absorber.
INSTALLATION
1. Properly prime the new front shock absorbers.2. Place a front spring insulator on the front shock absorber top stud
13-17 Nm (10-12 ft. lbs.).
13-17 Nm (10-12 ft. lbs.)
screws. Tighten to If the threads in the front suspension lower arm become stripped or damaged, the removed sc
34-46 Nm (25-33 ft. lbs.).3. Remove the safety stands and lower the vehicle.4. Place a nut/washer assembly on the f
> Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 7113
Suspension Strut / Shock Absorber: Service and RepairRear
WARNING:
-
IF EQUIPPED, THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE TURNE
-
ALL VEHICLES ARE EQUIPPED WITH GAS-PRESSURED SHOCK ABSORBERS WHICH WILL EX
REMOVAL
1. If equipped, turn the air suspension service switch, located in the luggage compartment, OFF.2. Raise and support
5. Remove the shock absorber upper retaining nut, washer and insulator from the stud on the upper side of the frame.
Replace
NOTE: - shock absorbers individually as required. It is not necessary to replace in pairs.
-
To assist in removing the upper attachment on shock absorbers using a plastic dust tube, place an open end wr
> Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 7114

6. Remove and discard the self-locking retaining nut, and disconnect the shock absorber lower stud from the mountin
assembly.
INSTALLATION
34-46 Nm (26-34 ft. lbs.). 76-103 Nm (57-75 ft. lbs.).1. Follow the removal procedure in reverse order.2. Tighten th
> Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Specifications
Suspension Travel Bumper: Specifications

Retaining Nuts .....................................................................................................................................................................
> Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Specifications > Page 7118
Suspension Travel Bumper: Service and Repair
REMOVAL
1. Raise vehicle on hoist.2. Remove nut and front suspension bumper.
INSTALLATION
34-47 Nm (26-34 ft. lbs.).1. Position front suspension bumper on front suspension lower arm.2. Install nut. Tighten t
> Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure
Article No.99-11-1
06/14/99
^
^
CONTENTS
> Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure >
Page 7123

GENERAL PROCEDURES
Diagnostic Theory

Diagnostic Process
Page 7124

Glossary of Terms
Page 7125

Dynamic Balance
Page 7126



Page 7127

Page 7128

Page 7129

Page 7130

a.
c.
d.
Page 7131

-
Vibrate Software(R)
Page 7132

ChassisEAR
EngineEAR

Page 7133

Tracing Powder
d.
Page 7134

Diagnostic Process
Page 7135

Page 7136

Page 7137

Page 7138

2. Pre-Drive Check
important
^
^
^
^
5. Road Test
Note:
^
Page 7139

speed-related.
^
^
^

^
Page 7140

Steering Input Test
^
Brake Test
^
^
^
^

^ WARNING:
^ CAUTION:
Page 7141

^
WARNING:
CAUTION:
Note:
^
^ Start the engine.
^ CAUTION:
Page 7142

1. Static operation
^
2. While cranking
3. At idle
^
1.
1. Speed related
-
Idle vibration
-
Page 7143

-

-
-
Airvaries
Noise Leak with
wind/vehicle
2. Acceleration
-
4. Braking.
^
^
^
5. Clutching

Page 7144

6. Shifting
^
8. Cruising speeds
1.

Page 7145

Page 7146

Page 7147

Page 7148

Page 7149

Page 7150

Page 7151

Page 7152

Page 7153

Page 7154

Page 7155

Page 7156

Page 7157

Page 7158

Page 7159

Page 7160

Page 7161

Page 7162

Page 7163

Page 7164

Page 7165

Page 7166

Page 7167

Page 7168

Page 7169

Page 7170

Page 7171

Page 7172

Page 7173

Page 7174

Page 7175

Page 7176

Page 7177

Page 7178

Page 7179

Pinpoint Tests
Page 7180

Page 7181

Page 7182

Page 7183

Page 7184

Page 7185

Page 7186

Page 7187

Page 7188

Page 7189

Page 7190

Page 7191

Page 7192

Page 7193

Page 7194

Page 7195

Page 7196

Page 7197

Page 7198

Page 7199

Page 7200

Page 7201

Page 7202

Page 7203

Page 7204

Page 7205

Page 7206

Page 7207

Page 7208

Page 7209

Page 7210

1. Open the hood.
2. Note:
Note:
4.
3. CAUTION:
Page 7211

3.
6.
7.
Page 7212

^
Page 7213

Page 7214

Page 7215

WARNING:
4. CAUTION:

WARNING:
WARNING:
Note:
1. WARNING:
Page 7216

CAUTION:
6.
^

Wheel Bearing Check
1. WARNING:

2. Note :
Page 7217

^
> Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Page 7218

-
-
-
REMOVAL

INSTALLATION
255-345 Nm (189-254 ft. lbs.).
200 Nm (147 ft. lbs.).

> Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications

> Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 > Recall - Vehicle
SAFETY RECALL00S13
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
Attachment

> Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Recalls for Vehicle Lifting: > 00S13 > Jul > 00 >
Recall - Vehicle Jacking Procedure > Page 7237

PLEASE NOTE
PROMPTLY CORRECT

LABOR ALLOWANCES
PARTS REQUIREMENTS


NOTE:

NOTE:
1.

1.


> Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting: > 00S13 > Ju
Procedure
SAFETY RECALL00S13
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
Attachment

> Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Lifting
: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 7249

PLEASE NOTE
PROMPTLY CORRECT

LABOR ALLOWANCES
PARTS REQUIREMENTS


NOTE:

NOTE:
1.

1.


> Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Technical Service Bulletins > Page 7256
CAUTION:
Hoist, Drive On
CAUTION:
Vehicle Lift Points
Jack, Floor
CAUTION:

-
CAUTION:
Hoist, Drive On
CAUTION:
Vehicle Lift Points
Jack, Floor
CAUTION:

-
> Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Recalls for Spare Tire: > 98B20 > Jun > 98 > Recall - Mini-Sp

98520
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIII^
^
New PartIV^

> Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Recalls for Spare Tire: > 98B20 > Jun > 98 >
Recall - Mini-Spare/Traction Control Problem > Page 7269


PLEASE NOTE
PROMPTLY CORRECT


LABOR ALLOWANCES
^ DOES II
CLAIMS PREPARATION
^ Enter using DWE.

SERVICE PROCEDURE



^




> Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spare Tire: > 98B20 > Jun
Control Problem

98520
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIII^
^
New PartIV^

> Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spare Tire:
> 98B20 > Jun > 98 > Recall - Mini-Spare/Traction Control Problem > Page 7283


PLEASE NOTE
PROMPTLY CORRECT


LABOR ALLOWANCES
^ DOES II
CLAIMS PREPARATION
^ Enter using DWE.

SERVICE PROCEDURE



^




> Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Technical Service Bulletins > Page 7292
Spare Tire: Specifications
Wheel Size ...........................................................................................................................................................................

> Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Service Precautions > Customer Safety Information
Spare Tire: Customer Safety Information

- Do not exceed the recommendations of load rating capacity specified on the vehicle safety certification decal loca
- A jack is provided for wheel and tire maintenance only.
- Never run engine when vehicle is supported by a jack.
> Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Service Precautions > Customer Safety Information > Page 7295
Spare Tire: Vehicle Damage Warnings
WARNING: NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, SUCH AS WHEN CHA
NOTE:
Extended use of other than conventional spare tires on a Traction-Lok rear axle could result in a permanent reduction
> Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment
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 THUNDERBIRD1997-2000 CONTOUR1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAUR

LINCOLN:
1997-1998 MARK VIII1997-2002 CONTINENTAL, TOWN CAR2000-2002 LS1998-2002 NAVIGATOR2002 BLA
MERCURY:1997 COUGAR1997-2000 MYSTIQUE1997-2002 GRAND MARQUIS, SABLE1999-2002 COUGAR19
ISSUEThe purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equ
This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. Th
ACTIONThe Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel
Service Information
NOTE
TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES
NOTE
WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTE
> Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment >
Page 7300

NOTE
UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPAB
1.
Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The
2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speed
NOTE
THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING T
3.
Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement ca
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 PAS
h. The following items may contribute to an assembly centering verification FAILURE.
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 proce
e. The following items may contribute to an assembly centering verification FAILURE.
6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode.
> Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7301
Article No.99-11-1
06/14/99
^
^
CONTENTS
Page 7302

GENERAL PROCEDURES
Diagnostic Theory

Diagnostic Process
Page 7303

Glossary of Terms
Page 7304

Dynamic Balance
Page 7305



Page 7306

Page 7307

Page 7308

Page 7309

a.
c.
d.
Page 7310

-
Vibrate Software(R)
Page 7311

ChassisEAR
EngineEAR

Page 7312

Tracing Powder
d.
Page 7313

Diagnostic Process
Page 7314

Page 7315

Page 7316

Page 7317

2. Pre-Drive Check
important
^
^
^
^
5. Road Test
Note:
^
Page 7318

speed-related.
^
^
^

^
Page 7319

Steering Input Test
^
Brake Test
^
^
^
^

^ WARNING:
^ CAUTION:
Page 7320

^
WARNING:
CAUTION:
Note:
^
^ Start the engine.
^ CAUTION:
Page 7321

1. Static operation
^
2. While cranking
3. At idle
^
1.
1. Speed related
-
Idle vibration
-
Page 7322

-

-
-
Airvaries
Noise Leak with
wind/vehicle
2. Acceleration
-
4. Braking.
^
^
^
5. Clutching

Page 7323

6. Shifting
^
8. Cruising speeds
1.

Page 7324

Page 7325

Page 7326

Page 7327

Page 7328

Page 7329

Page 7330

Page 7331

Page 7332

Page 7333

Page 7334

Page 7335

Page 7336

Page 7337

Page 7338

Page 7339

Page 7340

Page 7341

Page 7342

Page 7343

Page 7344

Page 7345

Page 7346

Page 7347

Page 7348

Page 7349

Page 7350

Page 7351

Page 7352

Page 7353

Page 7354

Page 7355

Page 7356

Page 7357

Page 7358

Pinpoint Tests
Page 7359

Page 7360

Page 7361

Page 7362

Page 7363

Page 7364

Page 7365

Page 7366

Page 7367

Page 7368

Page 7369

Page 7370

Page 7371

Page 7372

Page 7373

Page 7374

Page 7375

Page 7376

Page 7377

Page 7378

Page 7379

Page 7380

Page 7381

Page 7382

Page 7383

Page 7384

Page 7385

Page 7386

Page 7387

Page 7388

Page 7389

1. Open the hood.
2. Note:
Note:
4.
3. CAUTION:
Page 7390

3.
6.
7.
Page 7391

^
Page 7392

Page 7393

Page 7394

WARNING:
4. CAUTION:

WARNING:
WARNING:
Note:
1. WARNING:
Page 7395

CAUTION:
6.
^

Wheel Bearing Check
1. WARNING:

2. Note :
Page 7396

^
> Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 7397
Wheels: Specifications
Bolt Circle ............................................................................................................................................................................
Per Wheel .........................................................................................................................................................................
Lugs ......................................................................................................................................................................................
Steel ..................................................................................................................................................................................
Runout, Max
Radial ...............................................................................................................................................................................
Size .......................................................................................................................................................................................
> Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 7398
> Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation > Front
Wheels: Description and OperationFront
A front
Each sealedwheel
frontiswheel bearing
bolted to the is part hub
wheel of the wheel
and fronthub
discassembly.
brake rotor assembly.-
- The wheel hub assembly is attached to the front wheel spindle by a front axle wheel hub retainer.
> Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation > Front > Page 7401
Wheels: Description and OperationRear
TheThe
rearrear wheel
wheel bearingis and
assembly inner as
installed wheel bearing oil seal are pressed into the axle tube assembly.
follows:-
- The semi-floating axle shafts are held in the rear axle housing by the U-washer positioned in a slot on the axle sh
- The wheel and tire assembly is bolted to the axle shaft flange by the lug bolt and lug nut.
- Each rear wheel is bolted to rear hub assembly.
-
The rear disc brake rotor is mounted to lug bolts on the rear axle shaft hub flange. The wheel and tire assembly m
- The rear wheel bearing is pressed into the outer axle tube housing.
- The axle shaft is retained in the rear axle housing by the U-washer.
> Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Bends/Dents
Wheels: Service and RepairBends/Dents

> Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Bends/Dents > Page 7404
Wheels: Service and RepairHub Mounting Flange
Wheels: Service and RepairLeaks
DESCRIPTION
PROCEDURE
E7AZ-19544-A
6. Apply or heat
only enough equivalent
to meltmeeting Ford
the sealer, specification
then remove heatESA-M4G280-A flows. Apply
source. After servicing the allow
the leak, hot melt
thematerial
wheel toov
co
Wheels: Service and RepairMaintenance
Steel
CAUTION:
-
-
Aluminum
CAUTION:
NOTE:
During Tire Changes

WARNING:
-
-
-
NOTE:
-
PROCEDURE
-
-
NOTE:



- Cracks in metal.
Wheels: Service and Repair
Bends/Dents
Hub Mounting Flange
Leaks
DESCRIPTION
PROCEDURE

E7AZ-19544-A or equivalent meeting Ford specification ESA-M4G280-A flows. Apply the hot melt material ov
6. Apply only enough heat to melt the sealer, then remove heat source. After servicing the leak, allow the wheel to co
Steel
CAUTION:
-
-
Aluminum
CAUTION:
NOTE:
During Tire Changes

WARNING:
-
-
-
NOTE:
-
PROCEDURE
-
-
NOTE:

protective measure is of particular importance with drop-center tubeless rims as the air in the tire is contained by

- Cracks in metal.
Replacement
Are bent.
Wheels must be replaced when they:-
- Are dented or heavily rusted.
- Have air leaks (aluminum wheels can, in most cases, be serviced using the procedure under Cleaning and Inspect
- Have elongated bolt holes.
-
Have excessive lateral or radial runout. Wheels with a lateral or radial runout greater than the recommended spec
- load capacity
- diameter
- width
- offset and mounting configuration
An wheel andwheel
improper bearing lifeaffect:-
may
- ground and tire clearance
- speedometer and odometer calibrations
Corrosion buildup can result in wheels sticking to the hub rotor flange after extensive service. To prevent this from r
Replacements
WARNING:
NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, SUCH AS WHEN CHANGING A TIRE. T

NOTE:
Extended use of other than conventional spare tires on a traction-Lok rear axle could result in a permanent reduction i
REMOVAL
1. Remove the wheel cover by inserting end of wheel lug wrench and prying against wheel rim flange. Loosen, but d
CAUTION: Do not use heat to loosen a frozen wheel because heat can shorten the life of the wheel and damage
2. Raise the vehicle until the tire clears the floor.
CAUTION: To prevent damage, never use differential carrier as a lift point.
3. Remove the lug nuts. Remove the wheel from the wheel hub.4. If corrosion has formed around the center pilot hol
INSTALLATION
1. Clean all dirt and corrosion from the wheel hub mounting surface and center pilot hole of the wheel. Apply a thin
Grease to the axle pilot flange to reduce corrosion.
2. Place the wheel on the hub. Install the locking wire hubcap pedestal (if used) and the lug nuts. Tighten them altern
against the wheel hub.
115-142 Nm (85-104 ft. lbs.).3. Lower the vehicle. Tighten the lug nuts to
Valves
Replacement wheels may need to have an air valve installed. The air valve must be fully seated in the hole in the wheel
> Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure
Article No.99-11-1
06/14/99
^
^
CONTENTS
> Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness

GENERAL PROCEDURES
Diagnostic Theory

Diagnostic Process

Glossary of Terms

Dynamic Balance







a.
c.
d.

-
Vibrate Software(R)

ChassisEAR
EngineEAR


Tracing Powder
d.

Diagnostic Process




2. Pre-Drive Check
important
^
^
^
^
5. Road Test
Note:
^

speed-related.
^
^
^

^

Steering Input Test
^
Brake Test
^
^
^
^

^ WARNING:
^ CAUTION:

^
WARNING:
CAUTION:
Note:
^
^ Start the engine.
^ CAUTION:

1. Static operation
^
2. While cranking
3. At idle
^
1.
1. Speed related
-
Idle vibration
-

-

-
-
Airvaries
Noise Leak with
wind/vehicle
2. Acceleration
-
4. Braking.
^
^
^
5. Clutching


6. Shifting
^
8. Cruising speeds
1.




































Pinpoint Tests































1. Open the hood.
2. Note:
Note:
4.
3. CAUTION:

3.
6.
7.

^



WARNING:
4. CAUTION:

WARNING:
WARNING:
Note:
1. WARNING:

CAUTION:
6.
^

Wheel Bearing Check
1. WARNING:

2. Note :

^
> Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 7511

-
-
-
REMOVAL

INSTALLATION
255-345 Nm (189-254 ft. lbs.).
200 Nm (147 ft. lbs.).

> Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Description and Operation > Base Wheel Covers
Wheel Cover: Description and OperationBase Wheel Covers

-
The base wheel covers are stainless steel with integral retainer clips. The cross spoke steel covers are full plastic
-
Both wheel cover latches engage an undercut in the wheel at the safety bead. Use care to line up the cover windo
- When installing these wheel covers, do not force or hammer on the face of the wheel cover. They can be installed
> Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Description and Operation > Base Wheel Covers > Page 7521
Wheel Cover: Description and OperationWire Wheel Covers
A pedestal
Optional cup(anti-theft)
locking is attachedwheel
to thecovers
wheel are
withavailable.-
flanged lug nuts.
- A special bolt reaches through the center of the wheel cover to a pierce nut on top of the pedestal cup.
- A center wheel cover applique snaps onto the wheel cover, hiding the head of the lock bolt.
- Use care when installing or removing.
- A key wrench is used to lock the wheel cover to the pedestal cup and to remove the wheel cover applique.
- A decal on the underside of the luggage compartment door next to the jacking instructions contains the lock bolt
-
To allow vehicle service in the event the key has been misplaced, a Rotunda Locking Wire Wheel cover Master K
- The key has a circular keyway that is attached to the female slot in the anti-theft lock bolt.
> Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Cleaning
Wheel Cover: Service and RepairCleaning

CAUTION:
-
Do not use steel wool abrasive-type cleaner or strong detergents containing highly alkaline or caustic agents as da
-
To clean wheels, wheel covers and wheel cover appliques, use a mild soap and water solution and rinse thoroughly wit
> Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Cleaning > Page 7524
Wheel Cover: Service and RepairHub Caps
Part 1 Of 2
Part 2 Of 2
Remove or install the anti-theft lock bolt as follows:1. Insert the key into the slot of the lock bolt.2. Apply pressure o
and cap when installing the wheel cover. When installing these wheel covers, do not force or hammer on the face
NOTE:
Both the base and bright wire wheel covers are full plastic wheel covers with integral plastic latches which retai
> Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications

> Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence
Lug Nut Torque Patterns

> Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 7533
Wheel Fastener: SpecificationsWheel Tightening Torque

Lug Nuts ...........................................................................................................................................................................
Tighten lug nuts alternately to draw the wheel evenly against the wheel hub.
> Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 7534
Wheel Fastener: Description and Operation
NOTE:
- Aluminum wheels must use special bulge-type metric (M-12) lug nuts with enlarged chamfers or distortion of the
-
All vehicles use metric (M-12) lug nuts. Replacement lug nuts must be of the same type and thread size. All metr
ANTI-THEFT
The keywheels
Aluminum is attached to the wheel
on vehicles lug nut wrench,
are equipped stowedlug
with anti-theft with the(one
nuts spare
pertire.
wheel) that are installed during vehicle p
-
To allow vehicle service in the event the key has been misplaced, a Rotunda Master Service Tool Set 164-R3104
-
115-142Nm (85-104 ft. lbs.). The key has a circular keyway that is matched to the female slot in the anti-theft lu
> Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Fastener
Wheel Fastener: Service and RepairWheel Fastener
Anti-Theft
CAUTION:
-
Make sure the key is held square to the lug nut. If the key is on an angle, it may damage the key and the anti-thef
- DO NOT use a power impact wrench on the lug nut key.
115-142Remove or install the anti-theft lug nut as follows:1. Insert the key into the slot of the lug nut.2. Place the wh
Nm (85-104 ft. lbs.).
Regular
CAUTION
Failure to tighten lug nuts in a star pattern may result in high rotor runout, which will speed up the development of bra
- Install lug nuts using Rotunda Accutorq Lug Nut Sockets 164-R0303 or equivalent on a 1/2-inch drive impact wr
- 115-142 Nm (85-104 ft. lbs.).Tighten to
> Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Fastener > Page 7537
Wheel Fastener: Service and RepairWheel Stud
Front
REMOVAL
1. Raise vehicle on hoist.2. Remove wheel and tire assembly.3. Remove disc brake caliper and front disc brake rotor
INSTALLATION
1. Install lug bolt into wheel hub.2. Using a lug nut, seat wheel hub bolt into wheel hub.3. Install front disc brake roto
Rear
REMOVAL
2. Raise and support the vehicle.3. Remove the wheel and tire assembly.4. Remove the rear disc brake caliper, rear d
> Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Fastener > Page 7538

5. Using C-Frame and Clamp Assembly 211-023 (T74P-3044-A1), press the wheel hub bolt from its seat and discard
INSTALLATION
CAUTION: Never use air tools to install wheel hub bolts. The serrations can be stripped from the stud.
1. Insert a new wheel hub bolt in the hole in the axle flange, making sure serrations are aligned with those made by th
> Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Customer Interest for Accumulator HVAC: > 98-9-11 > May > 98 > A/C -
Accumulator HVAC: Customer InterestA/C - Poor Performance/Thumping Noise
Article No.98-9-11
05/11/98

^
SERVICE PROCEDURE
1.
2.
3.


DEALER CODING
CONDITION
BASIC PART NO. CODE
19E561 42
OASIS CODES: 208000, 208200, 208999, 702100, 702300

> Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator HVAC: > 98-9-11 > May
Thumping Noise
Accumulator HVAC: All Technical Service BulletinsA/C - Poor Performance/Thumping Noise
Article No.98-9-11
05/11/98

^
SERVICE PROCEDURE
1.
2.
3.


DEALER CODING
CONDITION
BASIC PART NO. CODE
19E561 42
OASIS CODES: 208000, 208200, 208999, 702100, 702300

> Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Page 7553
Accumulator HVAC: Specifications

A/C Accumulator Bracket Retaining Bolt ...........................................................................................................................
> Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Page 7554
Accumulator HVAC: Description and Operation

CAUTION:
Replacement of the suction accumulator/drier is necessary any time a major component of the refrigerant system is re
In addition to the preceding condition, the suction accumulator/drier should also be replaced if one of the following con
- 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 min
- There is evidence of moisture in the system such as internal corrosion of metal refrigerant lines or the refrigerant
NOTE:
The compressor oil from vehicles equipped with an FS-10 A/C compressor may have a dark color while maintaining a
When replacing the suction accumulator/drier, the procedure given here must be followed to make sure the total oil cha
- one or two 1/ 2-inch

Drain the oil from the removed suction accumulator/drier into a suitable measuring container. Drill holes in the b
- 60 ml (2 ounces)
Add the same amount plus of clean, new Motorcraft YN-12c refrigerant oil meeting Ford specification WSH-M1
> Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Guidelines
Accumulator HVAC: Service and RepairGuidelines

Replacement of the suction accumulator/drier is necessary whenever a major component of the refrigerant system is rep
- A/C condenser core
- A/C compressor
- A/C evaporator core
- Refrigerant hose(s) or line(s)
An A/C evaporator core orifice or O-ring seal is not considered a major component but the A/C evaporator core orifice
- There is evidence of moisture in the system such as internal corrosion of metal refrigerant lines, or the refrigerant
13 mm (0.5 inch)1. Drain the oil from the removed suction accumulator/drier into a suitable measuring container. D
the old suction accumulator/drier to make sure that all the oil has drained out.
NOTE: -
The compressor oil from vehicles equipped with the FS-10 A/C compressor may have a dark color while main
-
When replacing the suction accumulator/drier, the procedure given here must be followed to make sure that th
60 ml (2 ounces)2. Add the same amount of clean new refrigerant oil plus to the new suction accumulator/drier. Use
equivalent meeting Ford specification WSH-M1C231-B.
> Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Guidelines > Page 7557
Accumulator HVAC: Service and RepairRemoval and Installation

(3/8 inch)Spring Lock Coupling Disconnect Tool 412-026(T81P-19623-G1)

REMOVAL
1. Discharge the refrigerant from the A/C system following the recommended service procedures. Observe all safety
Repair/Discharging and Recovery
2. Disconnect the evaporator to compressor suction line from the suction accumulator/drier using Spring Lock Coupl
INSTALLATION
1. Using a new O-ring seal lubricated with clean Motorcraft YN-12c refrigerant oil meeting Fords specification WSH
suction the
2. Position accumulator/drier to the
A/C accumulator A/C on
bracket evaporator coreaccumulator/drier.
the suction outlet tube. Tighten connection
Align the A/C finger-tight
accumulatoronly.
bracket with th
the A/C evaporator core housing and install the retaining bolt. Loosen the connection of the suction accumulator/
6.6-9.4 N.m (59-83 lb-in)

3. Tighten the suction accumulator/drier to A/C evaporator core fitting using two wrenches.4. Tighten mounting brac
evaporator to compressor suction line to the suction accumulator/drier.
6. Leak-test, evacuate and charge the system following the recommended service procedures. Observe all safety prec
> Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Page 7558
Accumulator HVAC: Tools and Equipment


> Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator
C - Lack Of Temperature Control
Air Door Actuator / Motor: Customer InterestA/C - Lack Of Temperature Control
Article No.98-23-20
11/23/98
FORD:1997-98 CROWN VICTORIA, TAURUS
LINCOLN-MERCURY:1997 TOWN CAR1997-98 CONTINENTAL, GRAND MARQUIS, SABLE
LIGHT TRUCK: 1997-98 EXPLORER, MOUNTAINEER
This TSB article is being republished in its entirety to remove reference to the 1998 Town Car.
ISSUESome vehicles with a very low odometer reading may experience a lack of temperature control. This may be cau
ACTIONInstall the correct blend air door actuator. Refer to the following text and Actuator Chart to determine if the co
Vehicles which are equipped with manual and Electronic Automatic Temperature Control (EATC) use different actuato
1998 actuators differ from 1997 actuators on some vehicles (Crown Victoria/Grand Marquis, Continental, Explorer/Mo
Refer to the Actuator Chart to determine if the correct actuator is installed into the vehicle and service as required.
> Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air
Door Actuator / Motor: > 98-23-20 > Nov > 98 > A/C - Lack Of Temperature Control > Page 7568

Parts Block
SUPERSEDES: 98-10-3
982320A install Correct Blend Air 2.3 Hrs.
Door Actuator (CrownVictoria/Grand Marquis)
982320B Install Correct Blend Air 0.7 Hr.
Door Actuator(Taurus/Sable)
982320C Install Correct Blend Air 1.2 Hrs.

Door Actuator (Continental)
982320D Install Correct Blend Air 2.5 Hrs.
Door Actuator(Explorer/Mountaineer)
982320E Install Correct Blend Air 1.2 Hrs.

Door Actuator (Town Car)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19E616 12
OASIS CODES: 208000, 208100, 208200, 208300, 208999

> Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air D
Nov > 98 > A/C - Lack Of Temperature Control
Air Door Actuator / Motor: All Technical Service BulletinsA/C - Lack Of Temperature Control
Article No.98-23-20
11/23/98
FORD:1997-98 CROWN VICTORIA, TAURUS
LINCOLN-MERCURY:1997 TOWN CAR1997-98 CONTINENTAL, GRAND MARQUIS, SABLE
LIGHT TRUCK: 1997-98 EXPLORER, MOUNTAINEER
This TSB article is being republished in its entirety to remove reference to the 1998 Town Car.
ISSUESome vehicles with a very low odometer reading may experience a lack of temperature control. This may be cau
ACTIONInstall the correct blend air door actuator. Refer to the following text and Actuator Chart to determine if the co
Vehicles which are equipped with manual and Electronic Automatic Temperature Control (EATC) use different actuato
1998 actuators differ from 1997 actuators on some vehicles (Crown Victoria/Grand Marquis, Continental, Explorer/Mo
Refer to the Actuator Chart to determine if the correct actuator is installed into the vehicle and service as required.
> Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Air Door Actuator / Motor: > 98-23-20 > Nov > 98 > A/C - Lack Of Temperature Control > Page 7574

Parts Block
SUPERSEDES: 98-10-3
982320A install Correct Blend Air 2.3 Hrs.
Door Actuator (CrownVictoria/Grand Marquis)
982320B Install Correct Blend Air 0.7 Hr.
Door Actuator(Taurus/Sable)
982320C Install Correct Blend Air 1.2 Hrs.

Door Actuator (Continental)
982320D Install Correct Blend Air 2.5 Hrs.
Door Actuator(Explorer/Mountaineer)
982320E Install Correct Blend Air 1.2 Hrs.
Door Actuator (Town Car)
DEALER CODING
CONDITION
BASIC PART NO. CODE
19E616 12
OASIS CODES: 208000, 208100, 208200, 208300, 208999

> Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Page 7575
Blend Door Actuator

> Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Air Door Actuator
Air Door Actuator / Motor: Description and OperationAir Door Actuator
With Electronic Automatic Temperature Control

The vacuum control motors:
- are located on the A/C recirculating air duct and the heater air plenum chamber.
- direct system airflow to the vehicle interior as determined by the electronic automatic temperature control assemb
With Manual A/C-Heater

The vacuum control motors direct system airflow. There are two types of vacuum control motors used in the system:
- single-diaphragm for air inlet door operation
- double-diaphragm for air damper and windshield defroster door operation
Single-Diaphragm Vacuum Control Motor
Single-diaphragm motors have two positions:

- shaft extended with no vacuum applied
- shaft retracted with vacuum applied
Double-Diaphragm Vacuum Control Motor
Double-diaphragm motors have three positions:

- shaft fully extended with no vacuum applied to either port
- shaft halfway extended with vacuum applied to only one port
- shaft fully retracted with vacuum applied to both ports
The vacuum control motors are located on the A/C evaporator core housing.
> Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Air Door Actuator > Page 7578
Air Door Actuator / Motor: Description and OperationBlend Door Motor
The A/C electronic blend door actuator is located on top of the A/C evaporator core housing assembly.
- Its function is to move the A/C air temperature control door on command from the control assembly.
-
The A/C electronic blend door actuator contains a reversible electric motor and a potentiometer. The potentiomet
- five volt
A signal is applied to the ends of the potentiometer. The voltage available at the wiper indicates the position of th
> 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 RepairAir Door Actuator
Air Inlet Door
REMOVAL
1. Remove instrument panel lower insulator from bottom of instrument panel on passenger side by disengaging four
power point electrical connector.
2. Remove nut retaining harness/connector support bracket and position bracket side.3. Remove the spring nut retain
arm.
4. Disengage the vacuum control motor arm and washer from the crank arm.5. Disconnect the white vacuum hose co
control motor.
INSTALLATION
Heater Air Damper Door

> Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 7581

REMOVAL
1. Remove the heater air plenum chamber from the vehicle.2. Reach through the demister nozzle and duct opening an
INSTALLATION
1. Position the vacuum control motor to the mounting bracket and the heater air damper door bracket.2. Install two sc
Windshield Defroster Door

REMOVAL
1. Remove left lower dash insulation panel.2. Remove the pushnut retaining the vacuum motor arm to the floor-defro
INSTALLATION
1. Connect the yellow vacuum hose to the vacuum motor end nipple and the red vacuum hose to the vacuum motor s
control motor to the floor-defrost door crank arm and the motor mounting bracket.
2. Install two nuts to retain the vacuum control motor to the mounting bracket.3. Install a new pushnut to retain vacu
Air Door Actuator / Motor: Service and RepairBlend Door Motor
A/C Electronic Blend Door Actuator
Removal
1. Disconnect battery ground cable (14301).
2. Remove instrument panel (04320). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/S
3. Disconnect the A/C electronic blend door actuator electrical connector.
4. Remove four A/C electronic blend door actuator retaining screws.
5. Remove A/C electronic blend door actuator.
A/C Electronic Blend Door Actuator

1-5
Installation
1. Insert A/C electronic blend door actuator into A/C air temperature control door (19D842) (manually moving A/C a
help engage shaft).
2. Attach A/C electronic blend door actuator with four retaining screws.
3. Connect the A/C electronic blend door actuator electrical connector.
4. Install instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and

5. Connect battery ground cable.
> Heating and Air Conditioning > Air Duct > Component Information > Description and Operation
Air Duct: Description and Operation
The defroster, demister and register ducts distribute climate-controlled air from the heater air plenum chamber to the va
> Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > A/C Recirculating Air
Air Duct: Service and RepairA/C Recirculating Air

REMOVAL
1. Remove instrument panel.2. Remove the RH front wheel and tire assembly from vehicle.3. Remove the splash shi
disengage the top stud and remove the assembly from the vehicle.
INSTALLATION
1. Maneuver the A/C recirculating air duct assembly into position. Make sure the top and bottom studs protrude throu
top and dash panel.
2. Install the screw into the bottom LH side of the A/C recirculating air duct assembly but do not tighten.3. Install the
the plastic rivets.
7. Replace the RH front wheel and tire assembly.8. From the passenger compartment, tighten the previously installed
10. Check the system for proper operation.
> Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > A/C Recirculating Air > Page 7590
Air Duct: Service and RepairA/C Side Window Demister and Hose
REMOVAL
1. Remove the instrument panel.2. With the instrument panel lying on the front seat, pull off both RH A/C side wind
hose from demister nozzle and duct and window defogger nozzle.
INSTALLATION
Air Duct: Service and RepairDemister and Hose Assemblies
REMOVAL
1. Remove the instrument panel.2. Remove four screws retaining the demister nozzle and duct to the top of the instru
duct to the instrument panel reinforcement.
3. Remove two screws retaining both the RH A/C evaporator register duct and LH A/C evaporator register duct to th
reinforcement.
INSTALLATION
Air Duct: Service and RepairFloor Duct

REMOVAL
1. Remove rear seat air flow duct.
2. Pull instrument panel ash receptacle out to the stop.
3. Remove two screws retaining the ash receptacle retainer to the instrument panel.4. Lower front of instrument pane
instrument panel ash receptacle toward front of vehicle to disengage retaining clips.
outlet floor duct.

5. Disconnect ash receptacle wiring at connector.6. Remove two nuts retaining windshield defroster door vacuum co
INSTALLATION
Air Duct: Service and RepairRear Seat Air Flow

REMOVAL
1. Remove front seats.2. Remove RH and LH scuff plate covers by pulling up to release clips.3. Remove three retain
7. Pull carpet back to access rear seat air flow duct.8. Remove two push pins retaining rear seat air flow duct. Diseng
INSTALLATION
> Heating and Air Conditioning > Air Register > Component Information > Specifications
Air Register: Specifications

Instrument Panel Finish Panel to Instrument Panel (Screw) ...............................................................................................
> Heating and Air Conditioning > Air Register > Component Information > Specifications > Page 7597
Air Register: Description and Operation
The A/C register assemblies contain the following features:

- Retaining tabs lock the assemblies into the A/C register housings of the instrument trim panels.
- Horizontal panels swivel and direct the outlet air up or down while the louvers permit side-to-side air distribution
-
The thumbwheel at the LH side of the A/C register controls the damper door to allow full volume of air or positiv
If the thumbwheel becomes disengaged from the damper door actuating arm, it can be quickly re-engaged by
- The actuating arm is ramped along each side so that the thumbwheel tang will ride up the ramp and snap into
> Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Center
Air Register: Service and RepairCenter
NOTE:
- The instrument panel registers are serviced as assemblies only.
- The center and left A/C register assemblies are attached to the instrument panel finish panel by snap tabs at top an
REMOVAL
1. Disconnect battery ground cable.2. Remove radio chassis.3. Disengage snap tabs and remove instrument panel upp
INSTALLATION
> Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Center > Page 7600
Air Register: Service and RepairRight
NOTE: The instrument panel registers are serviced as assemblies only.
REMOVAL
1. Remove the instrument panel upper moulding to gain access to A/C register retaining screw.
NOTE: The instrument panel upper moulding is retained by snap-in tabs.
2. Remove passenger side air bag module.3. Remove the A/C register retaining screw.4. Remove the A/C register fro
NOTE: The A/C register assembly is secured in the instrument panel with snap tabs.
INSTALLATION
> Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations

> Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7604

> Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7605
REMOVAL
INSTALLATION
> Heating and Air Conditioning > Blower Motor > Component Information > Specifications
Blower Motor: Specifications

[a]A/C Blower Motor Current Draw
Setting Amperage / Voltage
Low ..................................................................................................................................................................................
[a] System in Maximum A/C Position
> Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor
Blower Motor: Service and RepairBlower Motor
REMOVAL
1. Working in RH wheel opening, remove three nuts securing radiator coolant recovery reservoir to fender splash pan
recovery reservoir away from blower motor.
2. Disconnect blower motor from main wiring harness at the snap-lock connector.3. Depress locking tab and slide tw
front fender splash panel. While still in the A/C evaporator core housing, lift the blower motor and A/C blower w
INSTALLATION
1. Position the blower motor and A/C blower wheel assembly into the A/C evaporator core housing by tilting it to the
mounting plate follows the contour of the front fender splash panel. Maneuver the assembly past the front fender
5.5-7.0 N.m (49-61 lb-in). 2. Install wiring support bracket to blower motor and install the four retaining screws (two
> Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor > Page 7611
Blower Motor: Service and RepairBlower Motor Wheel
REMOVAL
1. Remove blower motor and A/C blower wheel assembly as described in Heater Blower Motor and Blower Motor W
INSTALLATION
1. Align the flat surfaces on the inside diameter of the blower wheel hub with the flat surface of the motor shaft.2. Sl
> Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation > Blower Motor Switch Resistor
Blower Motor Resistor: Description and OperationBlower Motor Switch Resistor
The heater blower motor switch resistor, located in the engine compartment on the A/C evaporator core housing, opera
- Three resistance elements are mounted on the resistor board to provide four A/C blower motor speeds.
- Series resistance is added or bypassed in the A/C blower motor ground circuit to decrease or increase A/C blower
-
An overheating protective device (thermal limiter) prevents heat damage to the A/C evaporator core housing. Ov
> Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation > Blower Motor Switch Resistor > Page 7616
Blower Motor Resistor: Description and OperationBlower Motor Thermal Limiter
The thermal limiter, used in the heater blower motor switch resistor is located a predetermined distance away from the
- It serves as an over temperature protection fuse.
- 121C (250F)
It opens the resistor coil circuit when temperature of the thermal limiter reaches , interrupting blower motor opera
-
Spring contacts in the thermal limiter separate when the wax softens, causing an open circuit in the heater blower
> Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation > Page 7617
Blower Motor Resistor: Service and Repair
REMOVAL
1. Disconnect the wire harness snap lock connector from the heater blower motor switch resistor.2. Remove the two
INSTALLATION
> Heating and Air Conditioning > Blower Motor Switch > Component Information > Service and Repair

REMOVAL
INSTALLATION
> 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
> Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations

> Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 7627

> Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 7628

REMOVAL
NOTE:
INSTALLATION
> Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Technical Service Bulletins > Customer Interest for Cabin Ventilation Grille: > 99-4-5 > Mar > 99 > R
Whistling Noise
Cabin Ventilation Grille: Customer InterestRight Hand Windshield - Buzzing/Whistling Noise
Article No.99-4-5
03/08/99
NOISE - "BUZZING" FROM RIGHT HAND WINDSHIELD AREA AT 80 KM/H (50 MPH) OR ABOVE USING
NOISE - "WHISTLING" FROM RIGHT HAND WINDSHIELD AREA AT 80 KM/H (50 MPH) OR ABOVE USI
FORD: 1998 CROWN VICTORIA
LINCOLN-MERCURY: 1998 GRAND MARQUIS
ISSUEA "buzzing" and/or "whistling" noise from the RH side of the windshield area while driving at speeds above 80
ACTIONApply foam tape between the cowl vent screen and windshield. Refer to the following Service Procedure for d
SERVICE PROCEDURE
1. Remove RH side wiper arm.
2. Remove the screws retaining RH side cowl vent screen. Disconnect window washer hose. Remove cowl vent scre
3.
4.
Install the RH side cowl vent screen window washer hose. Position cowl vent screen and install screws. Torque s
5. Install RH side wiper arm.
(local Purchase Or Rotunda PVC Tape (Soft Foam)
Squeak And Rattle Kit)

WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper
Warranty Coverage
Apply 3 mm DESCRIPTION
OPERATION thick x 12 mm wide (1/8"x1/2") foamTIME
tape to the underside of the cowl vent screen (option: use PVC
990405A Perform Cowl Vent 0.3 Hr.

Screen Repair
DEALER CODING
CONDITION
BASIC PART NO. CODE
> Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Technical Service Bulletins > Customer Interest for Cabin Ventilation Grille: > 99-4-5
> Mar > 99 > Right Hand Windshield - Buzzing/Whistling Noise > Page 7637

54018A16 12
OASIS CODES: 108000, 208000, 208300, 208999, 701000, 702000, 702100, 702300
> Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cabin Ventilation Grille: > 99-4-5 >
Buzzing/Whistling Noise
Cabin Ventilation Grille: All Technical Service BulletinsRight Hand Windshield - Buzzing/Whistling Noise
Article No.99-4-5
03/08/99
SERVICE PROCEDURE
3.
4.

Warranty Coverage

Screen Repair
DEALER CODING
CONDITION
BASIC PART NO. CODE
> Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cabin Ventilation
Grille: > 99-4-5 > Mar > 99 > Right Hand Windshield - Buzzing/Whistling Noise > Page 7643

54018A16 12
OASIS CODES: 108000, 208000, 208300, 208999, 701000, 702000, 702100, 702300
> Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Electrical Specifications
Compressor Clutch: Electrical Specifications
A/C Clutch Air Gap Between A/C Clutch Pulley and A/C Clutch ......................................................................................
> Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Electrical Specifications > Page 7649
Compressor Clutch: Mechanical Specifications
Clutch Air Gap and Runout
A/C Clutch Air Gap Between A/C Clutch Pulley and A/C Clutch ......................................................................................
Torque
A/C Clutch Hub Retaining Bolt ...........................................................................................................................................
> Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7650
Compressor Clutch: Adjustments
1. Measure air gap between A/C clutch and A/C clutch pulley mating surfaces in three equally spaced locations with
measurements.
0.35-0.85 mm (0.014-0.033 inch)2. If each of the three measurements taken is not within , remove the A/C clutch.
3. Remove and measure the A/C clutch hub spacer. Select the appropriate thickness A/C clutch hub spacer to place th
Compressor Clutch: Service and Repair


Compressor Clutch Holding Tool 412-098 (T94P-19703-AH)
1. Hold A/C clutch with Compressor Clutch Holding Tool 412-098 (T94P-19703-AH) and remove the A/C clutch hu
2. Pull A/C clutch and A/C clutch hub spacers from A/C compressor shaft.
8 x 1.25 mm3. If A/C clutch cannot be pulled from A/C compressor shaft, screw an bolt into the shaft hole of the A/
shaft.

A/C Pulley Snap Ring - Removal/Installation
4. Remove A/C clutch pulley retaining snap ring.
5. Pull A/C clutch pulley from the A/C compressor.
INSTALLATION
1. Clean pulley bearing surface of A/C compressor head to remove any dirt or corrosion.2. Install A/C clutch pulley o
shaft.
6 mm5. Thread a new A/C clutch hub retaining bolt into end of A/C compressor shaft. Hold A/C clutch with Compr
11-14 N.m (98-123 lb-in).412-098 (T94P-19703-AH) and tighten A/C clutch hub retaining bolt to
10 times6. Check and adjust air gap as described in Adjustments.7. When installing a new A/C clutch, cycle it at idl
Compressor Clutch: Tools and Equipment

O-Ring Remover 100-010 (T71P-19703-C)

Snap Ring Remover 412-063 (T89P-19623-DH)
Shaft Seal Remover 412-059 (T89P-19623-BH)
Seal Protector 412-094 (T94P-19623-F)
Shaft Seal Replacer 412-058 (T89P-19623-AH)
> Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair
Compressor Clutch Coil: Service and Repair
Shaft Protector for Coil Removal 412-067 (T89P-19623-FH)

Puller-Differential Side Bearing 205-116 (T77F-4220-B1)
Coil Pressing Tool 412-065 (T89P-19623-EH)
Field Coil Replacer 412-078 (T91L-19623-CH)
NOTE:
The A/C clutch field coil is pressed on the front head of the A/C compressor. Special service tools are required to rem
REMOVAL
1. Remove the A/C compressor from the vehicle.2. Remove the A/C clutch and A/C clutch pulley. See: Compressor
CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged.
3. Note location of A/C clutch field coil electrical connector on A/C compressor housing prior to removal so that it c
location.
4. Install Shaft Protector for Coil Removal 412-067 (T89P-19623-FH) on the nose opening of the A/C compressor.
5. Install the Differential Side Bearing Puller 205-116 (T77F-4220-B1) on the A/C compressor. Place the tip of the p
pilot of the shaft protector and the jaws of the puller around the back edge of the A/C clutch field coil.
NOTE: Pulley Puller 412-D008 (D81P-19703-B) or equivalent may be used as an alternative to 205-116 (T77F-
6. Tighten the puller forcing screw to pull the A/C clutch field coil from the A/C compressor head.
CAUTION:
Failure to use Shaft Protector for Coil Removal 412-067 (T89P-19623-FH) may result in damage to the A/C com
> Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Page 7657

A/C Coil Pressing Tool - Installation
INSTALLATION
1. Clean the coil mounting surface on the front head to remove any dirt or corrosion.2. With the A/C compressor in a
A/C clutch field coil electrical connector is positioned correctly as noted during removal.
3. Place the Coil Pressing Tool 412-065 (T89P-19623-EH) with Field Coil Replacer 412-078 (T91L-19623-CH) in p
nose and to the inner radius of the A/C clutch field coil.
4. Position 2-Jaw Puller 205-D026 (D80L-1002-L) or equivalent on the A/C compressor and coil pressing tool. The j
firmly engaged with the rear side of the A/C compressor front mounts. The forcing screw must be piloted on the
5. Tighten the forcing screw with a hand wrench until the A/C clutch field coil is pressed on the A/C compressor fron
the A/C clutch field coil bottoms against the head at all points around the coil outer diameter.
CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged.
6. Install the A/C clutch pulley and A/C clutch on the A/C compressor.7. Check and adjust air gap as described in Ad
> Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair
Compressor Shaft Seal: Service and Repair

O-Ring Remover 100-010 (T71P-19703-C)

Snap Ring Remover 412-063 (T89P-19623-DH)
Shaft Seal Remover 412-059 (T89P-19623-BH)
Seal Protector 412-094 (T94P-19623-F)
Shaft Seal Replacer 412-058 (T89P-19623-AH)
REMOVAL
1. Remove A/C compressor from the vehicle.2. Remove A/C clutch from A/C compressor.
3. Remove shaft seal felt from nose of A/C compressor with O-Ring Remover 100-010 (T71P-19703-C).4. Blow any
compressor with a lint-free cloth to remove any oil and dirt.
5. Insert the tip of the Snap Ring Remover 412-063 (T89P-19623-DH) into one of the snap ring eyes.
6. Rotate the snap ring remover to position the tool tip and the snap ring eye closest to the A/C compressor shaft.
> Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Page 7661

7. Pull the snap ring remover up quickly while keeping the tool shaft against the side of the nose opening and remove
8. Position Shaft Seal Remover 412-059 (T89P-19623-BH) over A/C compressor shaft and push tool into nose of A/
shaft seal. Engage end of tool with inside diameter of shaft seal. While holding the hex part of the tool, turn tool h
INSTALLATION
1. Obtain a new A/C compressor shaft seal kit. Carefully remove the contents of the kit from the package. A plastic s
with each kit. Inspect the protector for any burrs or other damage. Seal Protector 412-094 (T94P-19623-F) can al
CAUTION:
Do not use a damaged seal protector. It can damage the lip of the new shaft seal. Obtain another shaft seal kit an
2. Using a clean, lint-free cloth, clean the A/C compressor shaft and the seal pocket inside the A/C compressor nose.
> Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Page 7662

CAUTION:
Do not allow any dirt or foreign materials to enter the A/C compressor. Internal system contamination can lead
3. Dip the seal protector and shaft seal in clean Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specifi
Position the shaft seal on the protector with the lip of the seal pointing toward the large end of the protector as sh
4. Place the seal protector with shaft seal over the end of the A/C compressor shaft.
5. Using Shaft Seal Replacer 412-058 (T89P-19623-AH), slowly push seal down shaft protector onto A/C compresso
10. Install A/C clutch on A/C compressor.11. Check and adjust the air gap as described in Adjustments. See: Compre
> Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations

Engine View
> Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7666

Relay Center (C110)

RELAYS
(PCM)
- engine start-up
REMOVAL
INSTALLATION
> Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications
Compressor Fitting HVAC: Specifications
Manifold Retaining Bolt ......................................................................................................................................................

> Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 7672
Compressor Fitting HVAC: Service and Repair


(3/4 inch)Spring Lock coupling Disconnect Tool 412-040 (T85L-19623-A)
REMOVAL
(5/8 inch)1. Discharge the refrigerant from the system. See: Service and Repair/Discharging and Recovery2. Loosen
condenser discharge line. Cap the A/C manifold and tube and A/C compressor to condenser discharge line to prev
(3/4 inch)8. Disconnect A/C manifold and tube using Spring Lock Coupling Disconnect Tool 412-040 (T85L-19623
suction line. Cap the A/C manifold and tube and evaporator to compressor suction line to prevent the entrance of
9. Remove bolt retaining A/C manifold and tube to A/C compressor and remove A/C manifold and tube from vehicle
and A/C compressor to prevent the entrance of dirt and moisture.
INSTALLATION
1. Position A/C manifold and tube in vehicle with protective caps installed.2. Lubricate new O-ring seals with clean
them in the O-ring seal grooves of the A/C compressor.
3. Apply Pipe Sealant with Teflon(K) D8AZ-19554-A or equivalent meeting Ford specifications WSK-M2G350-A2
of manifold retaining bolt.
4. Position A/C manifold and tube assembly to rear head of A/C compressor, making sure A/C manifold and tube pil
17-23 N.m (13-16 lb-ft).compressor port openings. Install A/C manifold and tube retaining bolt and tighten bolt
5. Connect other ends of suction and discharge lines into system using new O-ring seals lubricated with clean Motorc
17-23 N.m (13-16 lb-in).
6. Install nut retaining A/C compressor to condenser discharge line to stud on engine front cover. Tighten to 7. Reatta
> Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications
Condenser HVAC: Specifications

A/C Condenser Core to Radiator Support (Screw) ..............................................................................................................
> Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 7676
Condenser HVAC: Description and Operation
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
NOTE: Whenever an A/C condenser core is replaced, it is also necessary to replace the suction accumulator/drier.
Condenser HVAC: Testing and Inspection
ON-VEHICLE LEAK TEST
If an A/C evaporator core or A/C condenser core is suspected of leaking, the leak must be verified prior to removing th
1. Verify that the manifold gauge set is capable of holding vacuum.
1/4 inch
101 kPa (30a. Connect the red and blue hoses together using a flare coupling.b. Connect the gauge set yellow ho
in-Hg) of vacuum.
30 minutes. e. Allow the gauge set. with vacuum applied, to set for at least f.
If the gauge reading drops during that time, the gauge set hose connections, gauges or valves are leaking and s
2. Discharge the A/C system. See: Service and Repair/Discharging and Recovery3. Disconnect the suspect A/C evap
suction accumulator/drier attached to the core tubes. Refrigerant outgassing from oil and desiccant in the suction
4. Clean the evaporator or condenser core tube fittings. Refer to Spring Lock Coupling.5. Connect the appropriate tes
connections.
6. Connect the red and blue hoses from the manifold gauge set to the test fittings on the A/C evaporator core or A/C
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 availa
7. Open both gauge set valves and start the vacuum pump. Turn the A/C system blower on low and allow the vacuum
45 minutes 101 kPa (30 in-Hg) 45-minute
of after the gauge set low pressure gauge indicates . The evacuation is necessary to remove any refrigerant from

will occur. This will degrade the vacuum and appear as a refrigerant leak.
101 kPa (30 in-Hg)8. If the low pressure gauge reading will not drop to when the valves on the gauge and manifold
34 is
pump oroperating,
more kPaclose
(10 or
themore
gaugein-Hg) 101 kPa
set valves (30 in-Hg)
and observe the 10 minutes gauge. If the pressure rises rapidly to
low-pressure
If the low pressure gauge reading rises of vacuum from the position in , aleak 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 or an additional 30 min
- If a very small leak is suspected, allow the system to sit overnight with vacuum applied and check for vacuum
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
condenser core.
Condenser HVAC: Service and Repair
REMOVAL
NOTE:
- Whenever the A/C condenser core is replaced, it is necessary that the suction accumulator/drier also be replaced.
- If an A/C condenser core leak is suspected, the A/C condenser core must be leak-tested before it is removed from
1. Discharge the refrigerant from the A/C system at the service access valve located on the suction accumulator/drier
See: Service and Repair/Discharging and Recovery
2. Remove six push pins and radiator sight shield from vehicle.3. Remove battery from vehicle.4. Remove two upper
fan blade.
5. Disconnect wire connectors from mass air flow sensor (MAF sensor) and inlet air temperature sensor.6. Unfasten
10. With the aid of an assistant, carefully lift A/C condenser core off mounts on radiator and remove from vehicle.
INSTALLATION
2.9 ml (1 ounce)1. If the A/C condenser core is to be replaced, add of clean Motorcraft YN-12c refrigerant oil or eq
specification WSH-M1C231-B to the A/C condenser core.
2. With the aid of an assistant, carefully install A/C condenser core onto radiator and secure upper condenser mounti
8-11 N.m (71-97 lb-in)two retaining bolts. Tighten to .
3. Install radiator supports with retaining bolts.4. Place fan shroud into clips on lower radiator support of radiator. Se
25 mm (1 inch)clearance of approximately to fan blades.
5. Position air cleaner cover on the air cleaner body and secure retaining clips.6. Connect wire harness connector to m
meeting Ford specification WSH-M1C231-B.
8. Connect
7-9 N.mthe condenser
(62-79 lb-in).inlet
tube.tube to thepeanut
Tighten A/C compressor to condenser
fitting retaining nut to discharge line and the condenser outlet tube
9. Install battery.
10. Install radiator sight shield with six push pins.11. Leak-test, evacuate and charge the refrigerant system. Observe a
> Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
A/C-Heater Mode Switch

> Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 7683
Control Assembly: Description and Operation
The EATC assembly is located in the instrument panel and consists of the following:
- eleven push buttons
- a variable blower speed control wheel for manual input
- a digital display window for displaying set temperature, ambient temperature, function and DTCs
When the system is operating under AUTOMATIC control, the digital display window will show AUTO and the prefer
-
A/C blower motor speed, under automatic control, varies in response to in-car temperature selection, sunload sen
- 18C (65F) and 29C (85F)
Temperature may be increased or decreased in one degree increments between by pressing the red button toincre
Other control assembly features include:

- 16C (60F) 32C (90F)a setting for maximum cool and a setting for maximum heat.
- an OUTSIDE TEMP button which, when pressed, will display the air temperature outside the vehicle.
-
an OFF button which, if pressed, will apply vacuum to close the A/C air inlet duct door, shut off A/C blower mot
When the thumbwheel control for the blower motor is rotated out of the position it occupied under automatic control, it
- Under automatic control, A/C blower motor speed varies as required to accommodate the total automatic function
- Under manual control, A/C blower motor speed is constant based on the thumbwheel setting.
> Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Bulbs
Control Assembly: Service and RepairBulbs

REMOVAL
1. Remove A/C control.2. Place A/C control module upside-down on non-marring surface.3. Use a screwdriver to un
to new bulb and individually wrap with electrical tape. Insert new bulb into clip. Carefully resnap bezel to housin
INSTALLATION
> Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Bulbs > Page 7686
Control Assembly: Service and RepairClimate Control Assembly
REMOVAL
3. Remove four screws from the A/C control and pull the control out of the instrument panel.4. Remove the two elec
INSTALLATION
1. Connect the two electrical connectors and the vacuum connector to the A/C control.2. Position the A/C control in
Control Assembly: Service and RepairFunction Control Switch

REMOVAL
1. Remove A/C control.2. Remove knob.3. Disconnect vacuum bundle and electrical connector.4. Remove retaining
INSTALLATION
Control Assembly: Service and RepairSwitch Knobs

REMOVAL
1. To remove any of the three control knobs on the A/C control, grasp and pull rearward.
NOTE: Do not pry the knob off its shaft as damage to the surface of the air conditioner control assembly bezel m
2. If the D-shaped spring clip which sits inside the back end of the knob remains on shaft when knob is pulled off, re
and install on knob.
INSTALLATION
1. To install knob, align its keyed surface with mating surface on shaft. Press knob forward until fully seated in A/C
> Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips
Article No.00-21-3
10/16/00
SERVICE PROCEDURE
> Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips > Page
7693

a.
b.
a.
b.
a.
b.
c.
> Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control - Blower Control Service Tips > Page
7694

OASIS CODES: 208000, 208300, 208999

> Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Page 7695

> Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Blower Motor Speed Control

> Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Blower Motor Speed Control > Page 7698

> Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Blower Motor Speed Control > Page 7699

> Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Page 7700
-
> Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Page 7701
REMOVAL
INSTALLATION
> Heating and Air Conditioning > Coupler HVAC > Component Information > Specifications > Peanut Fitting Components
Coupler HVAC: SpecificationsPeanut Fitting Components
O-Ring ..................................................................................................................................................................................
> Heating and Air Conditioning > Coupler HVAC > Component Information > Specifications > Peanut Fitting Components > Page 7706
Coupler HVAC: SpecificationsSpring-Lock Coupling Components
O-Ring ..................................................................................................................................................................................
Service Kits
E35Y-19D690-D Contains:O-Rings.....................................................................................................................................
> Heating and Air Conditioning > Coupler HVAC > Component Information > Specifications > Peanut Fitting Components > Page 7707
Coupler HVAC: SpecificationsTorque Specification

Peanut Fitting Retaining Nut ...............................................................................................................................................
> Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation > Peanut Fitting
Coupler HVAC: Description and OperationPeanut Fitting
The A/C condenser core uses peanut shaped refrigerant fittings instead of spring lock couplings.
- the male and female blocks of the peanut fitting are retained with a nut.
- An O-ring seal is installed around the tube on the male block.
- The female block is attached to the tube and is not adjustable.
- Support the female fitting with a wrench to prevent twisting of the tubes.
- When properly assembled the male and female fittings should be flush.
> Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation > Peanut Fitting > Page 7710
Coupler HVAC: Description and OperationSpring Lock Coupling
REFRIGERANT LINE CONNECTIONS
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 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 coupling.
- 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 evaporator core spring lock couplings to indicate, during vehicle assembly,
- The indicator ring may also be used during service operations to indicate connection of the coupling.
> Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting
Coupler HVAC: Service and RepairPeanut Fitting

DISCONNECT
1. Remove refrigerant from system. See: Service and Repair/Discharging and Recovery2. Remove nut from peanut f
NOTE: Support the female fitting with a wrench to prevent tubes from twisting.
3. Pull peanut fitting apart.
4. Remove the O-ring seals from the male fitting using Plastic O-ring Tool F5VH-17B017-AA or equivalent. Do not
type of metal tool such as a screwdriver or pick. They could cause axial scratches across the O-ring grooves resul
CONNECT
1. Clean all dirt or foreign material from both pieces of fitting.2. Lubricate and install new O-ring seals on male fittin
4. Fit male and female ends of peanut fitting together.5. Tighten peanut fitting nut to 7-9 N.m (62-79 lb-in).
NOTE: When properly assembled the male and female fittings should be flush.
> Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting > Page 7713
Coupler HVAC: Service and RepairSpring Lock Coupling

COUPLING-DISCONNECT
(3/8 inch)
(1/2 inch)
(5/8 inch)
(3/4 inch)Spring Lock coupling Disconnect Tool ..............................................................................................................
1. Remove refrigerant from system. See: Service and Repair/Discharging and Recovery
2. Remove clip from spring lock coupling.
(3/8 inch) (1/2 inch)3. Fit Spring Lock Coupling Disconnect Tool 412-026 (T81P-19623-G 1) , 412-027 (T81P-1962
(5/8 inch) (3/4 inch)(T83P-19623-C) or 412-040 (T85L-19623-A) to the coupling.
4. Close tool and push into open side of cage to expand garter spring and release female fitting.
NOTE: The garter spring may not release if the tool is cocked while pushing it into the cage opening.
5. After garter spring is expanded, pull filling apart.

6. Remove tool from disconnected coupling.
7. Remove the green O-ring seals from the male fitting using Plastic Oring Tool F5VH-17B017-AA or equivalent. D
other type of metal tool such as a screwdriver or pick. They could cause axial scratches across the O-ring grooves
COUPLING-CLEANING
1/8 inch
1. Fabricate a cleaning tool from a diameter brazing rod.2. Cut an abrasive pad from maroon colored 3M Scotch Bri
coupling Size
Pad Size
.....................................................................................................................................................................................
3. Assemble the pad to the tool.4. Coat the abrasive pad with Motorcraft YN-12b refrigerant oil 228/144 or equivalen

1 minute 1500 rpm6. Polish for at moderate speed (less than ) or until the surface is clean and free of scratches or d
CAUTION:
Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent axial scratches which
7. Clean the fitting with a lint-free cloth.8. Inspect the surface for grooves or scratches. If grooves and scratches are s
300 mm (12 in)9. Clean the O-ring grooves with a length of natural fiber string by looping the string around the gro
and forth.
10. Remove any debris from the grooves with a lint-free cloth.
COUPLING-CONNECT
1. Check to make sure garter spring is in cage of male fitting. If garter spring is missing, install a new spring by push
spring is damaged, remove it from cage with a small wire hook (do not use a screwdriver) and install new spring.
2. Lubricate and install new green O-ring seals on male fitting.
NOTE:
Use only the specified green O-ring seals because they are made of a special material. The use of any O-ring sea

3. Lubricate male filling and green O-ring seals and inside of female fitting with clean refrigerant oil.
4. Install plastic indicator ring into cage opening if indicator ring is to be used.5. Fit female fitting to male fitting and
If plastic indicator ring is used, it will snap out of cage opening when coupling is connected to indicate engageme
6. If indicator ring is not used, check coupling engagement by making sure the garter spring is over flared end of fem
7. Install clip to spring lock coupling.

> Heating and Air Conditioning > Evaporator Case > Component Information > Description and Operation
Evaporator Case: Description and Operation
The A/C evaporator core housing is located on the engine side of the dash panel. It contains the following components:
- heater blower motor switch resistor
- blower motor
The heater air plenum chamber is located on the passenger side of the dash panel under the instrument panel. System ai
The heater air plenum chamber distributes system air within the passenger compartment. It contains the following com
- heater core
- A/C air temperature control door
- heater air damper door
- windshield defroster door
- two vacuum control motors
> Heating and Air Conditioning > Evaporator Case > Component Information > Description and Operation > Page 7720
Evaporator Case: Service and Repair

Spring Lock Coupling Disconnect Tool (3/8 inch) ..............................................................................................................
NOTE: Whenever the A/C evaporator core housing is replaced, it will be necessary to replace the suction accum
REMOVAL
1. Disconnect battery ground cable.2. Discharge the refrigerant from the A/C system while observing all safety preca
the openings to prevent dirt and excessive moisture from entering. Position the hose away from suction accumula
5. Disconnect the condenser to evaporator tube from the A/C evaporator core inlet tube using Spring Lock Coupling
openings. Position the condenser to evaporator tube away from the A/C evaporator core housing assembly.
6. Drain coolant from radiator. Save coolant for reuse.7. Loosen the hose clamps and disconnect the heater water hos
evaporator core housing.
9. Remove radiator coolant recovery reservoir. Position radiator coolant recovery reservoir forward, away from A/C

10. Disconnect A/C blower motor lead assembly from the main wiring harness and remove the hard-shell connector fr
control and the A/C cycling switch.
11. Disconnect the main wire harness (which crosses the A/C evaporator core housing) at the hard shell connecting po
A/C evaporator core housing.
12. Remove instrument panel lower insulator from bottom of instrument panel on passenger side by disengaging four
13. Fold carpeting back on the RH side of the floor. Remove the bottom LH screw that supports the A/C recirculating
remove the two screws (one drill point and one sheet metal) from the top of the A/C evaporator core housing.

17. Pull the bottom of the A/C evaporator core housing assembly away from the dash panel to disengage the two botto
A/C evaporator core housing assembly away from the dash panel, disengaging it from the top stud, and maneuve
INSTALLATION
1. Position the A/C evaporator core housing assembly next to the dash panel by maneuvering it down past the fender
housing assembly toward the dash panel while engaging the top dash panel stud into the A/C evaporator core hou
3. Install, but do not tighten, the three stud nuts.4. Install the two screws (one drill point and one sheet metal) and tig
correct hole located on top of the A/C evaporator core housing and to the right of the blower motor. Tighten the t
5. Position the wire harness connector across the A/C evaporator core housing assembly and attach the various conne
10. Install radiator coolant recovery reservoir to fender apron with two retaining nuts tightened to 5.5-7.0 N.m (49-61
Connect the condenser to evaporator tube to the evaporator inlet tube.
CAUTION: Make sure correct O-ring seals are installed whenever an A/C fitting is serviced. Leaks and refriger
14. Remove the plugs from the suction accumulator/drier outlet and the evaporator to compressor suction line and inst
clean refrigerant oil. Connect the evaporator to compressor suction line to the suction accumulator/drier.
15. From passenger side of dash panel, install retaining screw through A/C recirculating air duct into A/C evaporator c
Evaporator Case: Tools and Equipment

Spring Lock Coupling Disconnect Tool (3/8 inch) ..............................................................................................................

> Heating and Air Conditioning > Evaporator Core > Component Information > Specifications
Evaporator Core: Specifications

A/C Evaporator Core Housing to Dash Panel (Screw) ........................................................................................................
> Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 7727
Evaporator Core: Description and Operation
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 inl
- The next five plate/fin sections are partitioned to force the refrigerant to flow toward the other end of the A/C eva
-
The refrigerant then continues over to the remaining six and one half plate/fin sections and then moves out of the
- This S-pass flow pattern accelerates the flow of refrigerant and oil through the A/C evaporator core.
NOTE: Whenever an A/C evaporator core is replaced, also replace the suction accumulator/drier.
Evaporator Core: Testing and Inspection
ON-VEHICLE LEAK TEST
If an A/C evaporator core or A/C condenser core is suspected of leaking, the leak must be verified prior to removing th
1. Verify that the manifold gauge set is capable of holding vacuum.
1/4 inch
101 kPa (30a. Connect the red and blue hoses together using a flare coupling.b. Connect the gauge set yellow ho
in-Hg) of vacuum.
30 minutes. e. Allow the gauge set. with vacuum applied, to set for at least f.
If the gauge reading drops during that time, the gauge set hose connections, gauges or valves are leaking and s
2. Discharge the A/C system. See: Service and Repair/Discharging and Recovery3. Disconnect the suspect A/C evap
suction accumulator/drier attached to the core tubes. Refrigerant outgassing from oil and desiccant in the suction
4. Clean the evaporator or condenser core tube fittings. Refer to Spring Lock Coupling.5. Connect the appropriate tes
connections.
6. Connect the red and blue hoses from the manifold gauge set to the test fittings on the A/C evaporator core or A/C
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 availa
7. Open both gauge set valves and start the vacuum pump. Turn the A/C system blower on low and allow the vacuum
45 minutes 101 kPa (30 in-Hg) 45-minute
of after the gauge set low pressure gauge indicates . The evacuation is necessary to remove any refrigerant from

will occur. This will degrade the vacuum and appear as a refrigerant leak.
101 kPa (30 in-Hg)8. If the low pressure gauge reading will not drop to when the valves on the gauge and manifold
34 is
pump oroperating,
more kPaclose
(10 or
themore
gaugein-Hg) 101 kPa
set valves (30 in-Hg)
and observe the 10 minutes gauge. If the pressure rises rapidly to
low-pressure
If the low pressure gauge reading rises of vacuum from the position in , aleak 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 or an additional 30 min
- If a very small leak is suspected, allow the system to sit overnight with vacuum applied and check for vacuum
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
condenser core.
Evaporator Core: Service and Repair

NOTE:
- If an A/C evaporator core leak is suspected, the A/C evaporator core must be leak-tested before it is removed from
- Whenever the A/C evaporator core is replaced, it will be necessary to replace the suction accumulator/drier.
REMOVAL
1. Remove the A/C evaporator core housing from the vehicle.2. Remove six screws retaining the two halves of the A
seams.
4. Disconnect the suction accumulator/drier inlet from the evaporator core outlet tube.5. Remove the retaining screw
from the A/C evaporator core.
6. Remove retaining screw from inlet tube bracket and remove A/C evaporator core.
INSTALLATION
90 ml (3 ounces)1. Pour of clean Motorcraft YN-12c refrigerant oil meeting Ford specification WSH-M1C231-B di
replacement A/C evaporator core with the pipe held vertically so the oil will drain into the A/C evaporator core.

NOTE:
When replacing an A/C evaporator core in a refrigerant system, Motorcraft YN-12c refrigerant oil or equivalent
2. Attach the suction accumulator/drier to the evaporator core mounting bracket with a retaining screw.3. Install a ne
connect the suction accumulation drier inlet connection to the outlet tube of the evaporator core. Tighten using a
4. Position the A/C evaporator core assembly to the RH half of the A/C evaporator core housing.5. Apply Caulking C
around the evaporator core tubes.
6. Position the A/C evaporator core housing LH half and dash panel gasket to the case RH half.7. Install support stra
10. Install new A/C evaporator core orifice.11. Leak-test, evacuate and charge the refrigeration system following the r
> Heating and Air Conditioning > Orifice Tube <--> [Expansion Block/Orifice Tube] > Component Information > Specifications
Orifice Tube: Specifications
Color Code ...........................................................................................................................................................................

> Heating and Air Conditioning > Orifice Tube <--> [Expansion Block/Orifice Tube] > Component Information > Specifications > Page 7735
Orifice Tube: Locations

The A/C evaporator core orifice is located in the evaporator core inlet tube.
Orifice Tube: Description and Operation
The A/C evaporator core orifice has the following characteristics:

- is color coded orange
- 1.46 mm (0.058 inch)has a diameter of
- is located in the evaporator core inlet tube
- has filter screens located on the inlet and outlet ends of the tube body
The A/C evaporator core orifice is constructed with a plastic body, two screens and a small brass tube down the center
CAUTION:
Do not attempt to remove the A/C evaporator core orifice with pliers or to twist or rotate the A/C evaporator core orif
The A/C evaporator core orifice assembly is the restriction in the refrigerant circuit that creates the pressure drop neces
Operation is as follows:
- 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 bypassing the A/C ev
- Adjustment or services cannot be made to the A/C evaporator core orifice assembly. It must be replaced as a unit
NOTE: The A/C evaporator core orifice should be replaced whenever an A/C compressor is replaced.
Orifice Tube: Service and Repair


(1/2 inch)Spring Lock Coupling Disconnect Tool 412-027 (T81P-19623-G2)
REMOVAL
2. Disconnect the condenser to evaporator tube from the A/C evaporator core using Spring Lock Coupling Disconnec
(5/8 inch)(T83P-19623-C) . Cap the condenser to evaporator tube to prevent the entrance of dirt and excessive m
3. Pour a small amount of clean Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M
core inlet tube to lubricate the tube and O-ring seals during removal of the A/C evaporator core orifice from the e
4. Engage the Fixed Orifice Tube Tool 412-D001(D80L-19990-A) or equivalent with two tangs on the A/C evaporat
rotate the A/C evaporator core orifice in the A/C evaporator core tube as it may break off.
5. Hold the T-handle of the Fixed Orifice Tube Tool 412-D001(D80L- 19990-A) or equivalent to keep it from turnin
down against the A/C evaporator core tube until the A/C evaporator core orifice is pulled from the tube.a. To rem
equivalent into the A/C evaporator core tube and thread the screw end of the tool into the brass tube in the cen
NOTE:
If the A/C evaporator core orifice breaks in the A/C evaporator core tube, remove it from the tube with Brok
b. If only the brass center tube is removed during Step a., insert the screw end of Broken Orifice Tube Extractor 4
equivalent into the A/C evaporator core tube and screw the end of the tool into the A/C evaporator core orifice
INSTALLATION
1. Lubricate the O-ring seals on the A/C evaporator core orifice liberally with clean Motorcraft YN-12c refrigerant o
specification WSH-M1C231-B.
2. Place the A/C evaporator core orifice in the Fixed Orifice Tube Tool 412-D001(D80L-19990-A) or equivalent and
evaporator core tube until it is seated at the stop.
3. Remove the remover/replacer tool from the A/C evaporator core orifice.4. Using new O-ring seals lubricated with
connect the condenser to evaporator tube to the A/C evaporator core inlet tube.
Orifice Tube: Tools and Equipment


(1/2 inch)Spring Lock Coupling Disconnect Tool 412-027 (T81P-19623-G2)
Broken Orifice Tube Extractor 412-D002(D80L-19990-B)
Fixed Orifice Tube Tool 412-D001(D80L-19990-A)
> 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 Elec
Heater Core: Customer InterestA/C - Heater Core Electrolysis/Leakage

TSB 06-21-19
10/30/06

SERVICE PROCEDURE
> 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 7747

b.
NOTE

> Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C -

o.
NOTE
CAUTION
NOTE
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
> 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 - He
Heater Core: All Technical Service BulletinsA/C - Heater Core Electrolysis/Leakage

TSB 06-21-19
10/30/06

SERVICE PROCEDURE
> 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 7754

b.
NOTE

> Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct >

o.
NOTE
CAUTION
NOTE
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
> Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 7756
Heater Core: Testing and Inspection
WARNING: CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSAR
The heater core is an all-aluminum core which has two rows of flat tubes to maximize engine coolant flow. It is located
1. Inspect for visible evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak
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 should not have bee
2. Check the system for loose or overtightened heater water hose clamps. The clamps should be tightened to 1.7-2.4
can cause leakage at the heater water hose connection and damage the heater core tube.
PLUGGED HEATER CORE
Check to see that the engine coolant is at the proper level. Start the engine and turn on the heater. When the engine coo

PRESSURE TEST
Use Rotunda Radiator Pressure Tester 014-R1072 or equivalent to perform pressure test.
1. Drain the coolant from the cooling system.
NOTE: Due to space limitations, a bench test may be necessary for pressure testing.
101 mm (4 inches)2. Disconnect the heater water hoses from the heater core tubes.3. Install a short piece of heater w
4. Fill the heaterorcore
014-R1072 and heater
equivalent water
in the hoses
heater with
water water
hose andSecure
ends. installthe
Plug BT-7422-B
heater and adapter
water hoses, BT-7422-A
plug and from
adapter with R
hose
241 kPa (35 psi)

three minutes
5. Attach the pump and gauge assembly from Rotunda Radiator Pressure Tester 014-R1072 or equivalent to the adap
core from the vehicle and perform bench test.

BENCH TEST
Use Rotunda Radiator Pressure Tester 014-R1072 or equivalent to perform bench test.
101 mm (4 inch)1. Drain all coolant from the heater core.2. Remove heater core from A/C evaporator housing.3. Co
014-R1072 or equivalent to the adapter.
241 kPa (35 psi)
4. Apply of air pressure to the heater core. Submerge the heater core in water.5. If a leak is observed, service or repl
> Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core
Heater Core: Service and RepairBack Flushing-Heater Core

CAUTION: The heater core must be back-flushed separately from the engine cooling system for proper back-flush wa
All engine cooling system flushing and back-flushing procedures must include a separate back-flushing of the heater co
The correct heater core back-flushing procedure is as follows:
1. Disconnect the heater core outlet heater water hose from the return fitting and install a female garden hose-end fitt
outlet heater water hose. Secure with a hose clamp.
2. Connect the female end of the outlet heater water hose to the male end of a water supply garden hose.3. Disconnec
tubes. Allow full water pressure to flow for approximately five minutes.
6. If a water valve is installed in the heater core inlet heater water hose, apply vacuum to the water valve vacuum mo
operation of the water valve and proper closure with no water leakage. Replace the water valve if required.
7. Remove the hose clamp and female garden hose-end adapter from the end of the outlet heater water hose and reco
hose onto the water pump fitting and heater return fitting.
8. Connect the inlet heater water hose onto the cylinder block fitting and intake manifold fitting.9. Fill the engine coo
Engine Coolant F6AZ-19544-AA (orange), or equivalent and water.
10. Test the system for proper heater performance with the specified engine cooling system conditions.
> Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 7761
Heater Core: Service and RepairRemoval and Installation
REMOVAL
1. Remove the heater air plenum chamber assembly. See: Heater Air Plenum Chamber/Service and Repair2. Remove
INSTALLATION
1. Carefully install heater core assembly into the heater air plenum chamber assembly. Visually check to make sure h
positioned.
2. Position the heater core cover and install the four retaining screws.3. Install the heater air plenum chamber assemb
> Heating and Air Conditioning > Heater Air Plenum Chamber <--> [Heater Core Case] > Component Information > Service and Repair
Heater Air Plenum Chamber: Service and Repair
REMOVAL
1. Remove heater outlet floor duct.2. Remove instrument panel.3. Disconnect the heater water hoses from the heater
10. Disconnect connectors to A/C electronic blend door actuator and electronic module on side of heater air plenum c
INSTALLATION
1. Route the vacuum supply hose through the dash panel and seat the grommet in the opening.2. Position the heater a
wire harness
3. Rotate connector
the heater to A/C
air plenum electronic
chamber blend the
up behind doorinstrument
actuator and electronic
panel module
and position theon side air
heater of heater
plenumairchamber
plenum t
heater core tubes and mounting studs through their respective holes in the dash panel and the A/C evaporator core
4. Install three nuts on the studs along the lower flange and one on the upper flange of the heater air plenum chamber
floor duct.
9. Connect the sensor tube to the evaporator case connector on EATC-equipped vehicles.
10. Connect vacuum supply hose to vacuum supply.11. Unplug the heater core tubes arid connect the heater water hos
> Heating and Air Conditioning > Heater Air Plenum Chamber <--> [Heater Core Case] > Component Information > Service and Repair > Page 7765

13. Install heater outlet floor duct.14. Install instrument panel.
> 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 Ele

TSB 06-21-19
10/30/06

SERVICE PROCEDURE
> Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C -

b.
NOTE

> Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C -

o.
NOTE
CAUTION
NOTE
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
> 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 - He

TSB 06-21-19
10/30/06

SERVICE PROCEDURE
> Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct >

b.
NOTE

> Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct >

o.
NOTE
CAUTION
NOTE
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
> Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 7783

> Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 7784
REMOVAL
INSTALLATION
hoses.
> Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications
High Pressure Safety Valve HVAC: Specifications

Open .....................................................................................................................................................................................
> Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications > Page 7788
High Pressure Safety Valve HVAC: Description and Operation

An A/C compressor pressure relief valve has been incorporated in the compressor's A/C manifold and tube to:
- 3103 kPa (450 psi)relieve unusually high refrigerant system discharge pressure buildups, 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.
The A/C compressor pressure relief valve is located in the A/C manifold and tube.
> Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications > Page 7789
High Pressure Safety Valve HVAC: Service and Repair

REMOVAL
1. Discharge refrigerant from system. Observe all safety precautions. See: Service and Repair/Discharging and Reco
INSTALLATION
> Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 98-9-11 > May > 98 > A/C - Poor
Hose/Line HVAC: Customer InterestA/C - Poor Performance/Thumping Noise
Article No.98-9-11
05/11/98

^
SERVICE PROCEDURE
1.
2.
3.


DEALER CODING
CONDITION
BASIC PART NO. CODE
19E561 42
OASIS CODES: 208000, 208200, 208999, 702100, 702300

> Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 98-9-11 > May > 98
Noise
Hose/Line HVAC: All Technical Service BulletinsA/C - Poor Performance/Thumping Noise
Article No.98-9-11
05/11/98

^
SERVICE PROCEDURE
1.
2.
3.


DEALER CODING
CONDITION
BASIC PART NO. CODE
19E561 42
OASIS CODES: 208000, 208200, 208999, 702100, 702300

> Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 7803
Hose/Line HVAC: Specifications

A/C Hose Clamps ................................................................................................................................................................
> Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line
Hose/Line HVAC: Service and RepairA/C Discharge Hose/Line

REMOVAL
2. Remove A/C pressure cut-off switch.3. Loosen nut retaining A/C compressor to condenser discharge line to stud o
INSTALLATION
1. With the protective caps installed, route the new refrigerant line.2. Remove protective caps then connect the A/C c
7-9 N.m(62-79 lb-in). Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231
17-23 N.m (13-16 lb-in)
3. Install nut retaining A/C compressor to condenser discharge line to stud on engine front cover. Tighten to .4. Insta
> Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line > Page 7806
Hose/Line HVAC: Service and RepairA/C Liquid Hose/Line

REMOVAL
2. Disconnect and remove the condenser to evaporator tube from between A/C evaporator core and A/C condenser co
Disconnect Tool 412-038 (T83P-19623-C).
INSTALLATION
1. With the protective caps installed, route the new refrigerant line.2. Remove protective caps then connect the conde
7-9N.m (62-79 lb-in). YN-12c refrigerant oil meeting Ford specification WSH-M1C231-B (refer to Spring Lock
3. Leak-test, evacuate and charge the refrigerant system following the recommended procedures and safety precautio
> Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line > Page 7807
Hose/Line HVAC: Service and RepairA/C Suction Hose/Line
(5/8 inch)Spring Lock coupling Disconnect Tool 412-038 (TS3P- 19623-C)

(1/2 inch)Spring Lock coupling Disconnect Tool 412-027 (T81P-19623-G2)
NOTE: Whenever a refrigerant line is replaced, it will be necessary to replace the suction accumulator/drier.
REMOVAL
2. Remove the A/C cycling switch.3. Disconnect and remove the evaporator to compressor suction line using Spring
412-027 (T81P-19623-G2).
INSTALLATION
1. With the protective caps installed, route the new refrigerant line.2. Remove protective caps then connect the evapo
Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B.
3. Install the A/C cycling switch.4. Leak-test, evacuate and charge the refrigerant system following the recommended
> Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Page 7808
Hose/Line HVAC: Tools and Equipment

(3/8 inch)
(1/2 inch)
(5/8 inch)
(3/4 inch)
Spring Lock coupling Disconnect Tool ....................................................................................................................... 412
> Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation
Receiver Dryer: Description and Operation

CAUTION:
Replacement of the suction accumulator/drier is necessary any time a major component of the refrigerant system is re
- There is evidence of moisture in the system such as internal corrosion of metal refrigerant lines or the refrigerant
NOTE:
The compressor oil from vehicles equipped with an FS-10 A/C compressor may have a dark color while maintaining a
When replacing the suction accumulator/drier, the procedure given here must be followed to make sure the total oil cha
- one or two 1/ 2-inch

Drain the oil from the removed suction accumulator/drier into a suitable measuring container. Drill holes in the b
- 60 ml (2 ounces)
Add the same amount plus of clean, new Motorcraft YN-12c refrigerant oil meeting Ford specification WSH-M1
> Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair > Removal and Installation
Receiver Dryer: Service and RepairRemoval and Installation


REMOVAL
INSTALLATION
1. Using a new O-ring seal lubricated with clean Motorcraft YN-12c refrigerant oil meeting Fords specification WSH
suction the
2. Position accumulator/drier to the
A/C accumulator A/C on
bracket evaporator coreaccumulator/drier.
the suction outlet tube. Tighten connection
Align the A/C finger-tight
accumulatoronly.
bracket with th
the A/C evaporator core housing and install the retaining bolt. Loosen the connection of the suction accumulator/
6.6-9.4 N.m (59-83 lb-in)

3. Tighten the suction accumulator/drier to A/C evaporator core fitting using two wrenches.4. Tighten mounting brac
evaporator to compressor suction line to the suction accumulator/drier.
> Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair > Removal and Installation > Page 7814
Receiver Dryer: Service and RepairReplacement Guidelines

Replacement of the suction accumulator/drier is necessary whenever a major component of the refrigerant system is rep
- A/C condenser core
- A/C compressor
- Refrigerant hose(s) or line(s)
An A/C evaporator core orifice or O-ring seal is not considered a major component but the A/C evaporator core orifice
- There is evidence of moisture in the system such as internal corrosion of metal refrigerant lines, or the refrigerant
13 mm (0.5 inch)1. Drain the oil from the removed suction accumulator/drier into a suitable measuring container. D
the old suction accumulator/drier to make sure that all the oil has drained out.
NOTE: -
The compressor oil from vehicles equipped with the FS-10 A/C compressor may have a dark color while main
-
When replacing the suction accumulator/drier, the procedure given here must be followed to make sure that th
60 ml (2 ounces)2. Add the same amount of clean new refrigerant oil plus to the new suction accumulator/drier. Use
> Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair > Page 7815
Receiver Dryer: Tools and Equipment


> Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants
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 LTD1985-1988 EXP1985-1994 TEMPO1985-1997 THUNDERBIRD1985-2000 CROWN VICTOR
LINCOLN:1985-1992 MARK VII1985-2000 CONTINENTAL, TOWN CAR1993-1998 MARK VIII2000 LS1998-20

MERCURY:1985-1986 MARQUIS1985-1987 LYNX1985-1994 TOPAZ1985-1997 COUGAR1985-2000 GRAND M
MERKUR:1985-1989 XR4TI 1988-1989 SCORPIO
> Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 7820

This TSB article is being republished in its entirety to add model year vehicles
ISSUEA number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop
ACTIONRefrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to pre
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 M
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 Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Li
The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditionin
The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity p
The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyz

when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/
Recovery of Contaminated Refrigerant
If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling e
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
3.
Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing
Repairing A Contaminated A/C System
Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommen
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 a
^ 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

^ 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

Article No.98-12-5
06/22/98

ACTION

SUPERSEDES: 96-15-5

(R-12) Recovery
DEALER CODING
CONDITION
BASIC PART NO. CODE
19703 49
OASIS CODES: 208000, 208999
Service Procedure
CAUTION
NOTE
CAUTION
1.
3.
CAUTION
4.

b.
NOTE:
8.
CAUTION
^
9.
11.

13.
NOTE:

F73Z-19577-AA
F7AZ-19589-DA
NOTE
> Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications
Refrigerant: Capacity Specifications
Refrigerant Capacity ............................................................................................................................................................

> Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 7830
Refrigerant: Fluid Type Specifications

Refrigerant Type ..................................................................................................................................................................
> Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement
Article No.98-12-5
06/22/98

ACTION
> Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement >
Page 7835

SUPERSEDES: 96-15-5

(R-12) Recovery
DEALER CODING
CONDITION
BASIC PART NO. CODE
19703 49
OASIS CODES: 208000, 208999
Service Procedure
CAUTION
NOTE
CAUTION
1.
3.
CAUTION
4.
Page 7836

b.
NOTE:
8.
CAUTION
^
9.
11.
Page 7837

13.
NOTE:

F73Z-19577-AA
F7AZ-19589-DA
NOTE
> Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications
Refrigerant Oil: Capacity Specifications
Oil Capacity .........................................................................................................................................................................

> Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 7842
Refrigerant Oil: Fluid Type Specifications

Polyalkylene Glycol (PAG) ........................................................................................................................................ WSH
> Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 7843
Refrigerant Oil: Service and Repair
The A/C compressor uses a special refrigerant oil, PAG Compressor Oil F7AZ-19589-DA or Motorcraft YN-12c or eq
It is important that only the specified type and quantity of refrigerant oil be used in the A/C compressor. If there is surp
DURING A/C COMPRESSOR REPLACEMENT
Whenever the A/C compressor is replaced and evidence of debris is present within the A/C system, the following must
- replace suction accumulator/drier
- replace the A/C evaporator core orifice
- clean the A/C system by flushing or filtering
NOTE: Service A/C compressors are shipped without compressor oil.
When reinstalling the existing A/C compressor or installing a new A/C compressor, the A/C compressor must be servic
1. Obtain a clean container that can also be used as a measuring device.2. Place the A/C clutch on the A/C compresso
89 and 142 ml (3 and 5 ounces) 30 ml (13. Rotate the shaft by hand six to eight revolutions, collecting the oil in a c
ounce)
of clean PAG Compressor Oil F7AZ-19589-DA or Motorcraft YN-12c or equivalent meeting Ford specification
142 ml (5 ounces)5. If the amount of oil that was removed from the old A/C compressor is greater than , pour the sam
89 ml (3 ounces) 89 ml (3 ounces)6. If the amount of refrigerant oil that was removed from the old A/C compressor
> Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > A/C Cycling Switch
Close ....................................................................................................................................................................................
> Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > A/C Cycling Switch > Page 7848
Open .....................................................................................................................................................................................
> Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch

DUAL FUNCTION

- 3103 kPa (450 psi)
> Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch > Page 7851
- 152-193 kPa (22 to 28 psi)
- 7-10C (45-50F)
-
-
> Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch
REMOVAL
INSTALLATION
> Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch > Page 7854
REMOVAL
INSTALLATION
> Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations

Engine View
> Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 7859

Relay Center (C110)

RELAYS
(PCM)
- engine start-up
REMOVAL
INSTALLATION
> Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control - Blower Control Servi
Article No.00-21-3
10/16/00
SERVICE PROCEDURE
> Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control -
Blower Control Service Tips > Page 7866

a.
b.
a.
b.
a.
b.
c.
> Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Climate Control -
Blower Control Service Tips > Page 7867

OASIS CODES: 208000, 208300, 208999

> Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 7868

> Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Blower Motor Speed Control

> Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Blower Motor Speed Control > Page 7871

> Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Blower Motor Speed Control > Page 7872

> Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Page 7873
-
> Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Page 7874
REMOVAL
INSTALLATION
> Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations

> Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7879

> Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7880
REMOVAL
INSTALLATION
> Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair

REMOVAL
INSTALLATION
> Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations

> Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 7887

> Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 7888

REMOVAL
NOTE:
INSTALLATION
> Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > A/C Cycling Switch
Close ....................................................................................................................................................................................
> Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > A/C Cycling Switch > Page 78
Open .....................................................................................................................................................................................
> Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cuto

DUAL FUNCTION

- 3103 kPa (450 psi)
> Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cuto
- 152-193 kPa (22 to 28 psi)
- 7-10C (45-50F)
-
-
> Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch
REMOVAL
INSTALLATION
> Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch > Pa
REMOVAL
INSTALLATION
> Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations

> Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 7903

-
> Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 7904

REMOVAL
INSTALLATION
> Heating and Air Conditioning > Service Port HVAC > Component Information > Locations
Service Port HVAC: Locations
The low-pressure service access gauge port valve is located on the side of the suction accumulator/drier.
The high-pressure service access gauge port valve is located on the A/C compressor to condenser discharge line.
> Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 7908
Service Port HVAC: Description and Operation
The high-side fitting is the largest. Special couplings are required to connect service equipment to both the high-side an
- Quick disconnects must be used to connect a manifold gauge set to the system.
- Always install the A/C charging valve caps on the service access gauge port valves after servicing the refrigerant
The service gauge port valves are an integral part of the refrigeration line or component. The Schrader-type valve core
> Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations

> Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 7912

-
> Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 7913

REMOVAL
INSTALLATION
> Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Description and Operation
Vacuum Harness HVAC: Description and Operation

Mini-tube vacuum hoses are used in the vacuum hose harness.
- They provide greater flexibility with less tendency to collapse and are less susceptible to pinching.
- Do not pinch the mini-tube vacuum hoses during diagnosis.
> Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Description and Operation > Page 7917
Vacuum Harness HVAC: Service and Repair
1/8 inch
1/8 inch
Mini-tube vacuum hoses are provided in the vacuum hose harness assemblies. They provide greater flexibility with less
1/8 inch 25 mm (1 inch)1. Measure length of damaged area of the mini-tube vacuum hose.2. Cut a piece of standard
hose.
3. Cut off the mini-tube vacuum hose on each side of damaged area.4. Dip the mini-tube hose ends in commercially
vacuum hose.
WARNING: READ THE WARNING INFORMATION ON THE SOLVENT PRODUCT LABEL.
9 mm (3/8 inch) 1/8 inch
5. Insert ends of the mini-tube vacuum hose approximately into ends of standard service vacuum hose section.6. Sh
> Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Service and Repair
Vacuum Reservoir HVAC: Service and Repair

REMOVAL
1. Remove relay module.2. Remove two nuts retaining speed control vacuum reservoir to inner fender.3. Disconnect
INSTALLATION
> Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming

WARNING:^
air bag module.
one minute (ECS)

WARNING:^
air bag module.

> Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 7927

> Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 7928

> Restraint Systems > Air Bag Systems > Air Bag > Component Information > Specifications
Air Bag: Specifications

10.2-13.8 (90-122)Driver Air Bag Module-to-Steering Wheel Screws...............................................................................
7.6-10.4 (68-92)Lower Passenger Air Bag Module Retaining Bolts ...................................................................................
2.1-2.9 (19-25)Upper Passenger Air Bag Module Retaining Bolts .....................................................................................

> Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Air Bag Module
> Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Air Bag Module > Page 7934
> Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Driver Air Bag Module
Air Bag: Description and OperationDriver Air Bag Module
NOTE:
The driver air bag module is serviced as a complete assembly. Perform proper disposal procedure. See: Service and R
DESCRIPTION
The driver air bag module is mounted in the center of the steering wheel. The driver air bag module consists of the follo
^ inflator
^ air bag
^ mounting plate and retainer ring
^ steering wheel trim cover
Inflator
TheWhen theassembly
inflator sensor closes,
is not signaling a crash,
a serviceable electrical energy flows to the air bag inflator.
item.^
^ Inside the inflator, an igniter converts the electrical signal to thermal energy (heat), causing the ignition of the
^
This ignition reaction causes combustion of the sodium azide/cupric oxide gas generant in the inflator, produc
Air Bag
Theisdriver
constructed of nylon.
air bag:^
^ 672 mm (26.5 inches)is in diameter.
^ 0.057 cubic meter (2.0 cubic feet) 40 millisecondsfills to a volume of about in approximately .
^ is not a serviceable item.
Mounting Plate and Retainer Ring

Theattach and seal
mounting platethe airretainer
and bag assembly
ring:^ to the inflator.
^ also attach the trim cover and mount the entire driver air bag module to the steering wheel.
^ are components of the driver air bag module and cannot be serviced.
Steering Wheel Trim Cover

Theencases
steeringdriver
wheelair bagcover:^
trim module.
^ has moulded-in tear seams that separate to allow inflation of the bag.
^ is a component of the driver air bag module and is not serviceable.
^ must not be repainted for any reason.
> Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Driver Air Bag Module > Page 7937
Air Bag: Description and OperationPassenger Air Bag Module
NOTE:
The passenger air bag module is serviced as a complete assembly. Perform proper disposal procedure. See: Service an
DESCRIPTION
The passenger air bag module is mounted in the RH position of the instrument panel above the glove compartment. The
^ inflator
^ air bag
^ reaction housing with mounting hardware
^ trim cover
Inflator
TheAn igniter inside
passenger air bagthe inflator
inflator converts
operates as electrical
follows:ênergy to thermal energy (heat), causing ignition of the gas ge
^ The ignition reaction causes combustion of the potassium nitrate gas generant, producing nitrogen to fill the b
^ It includes a low pressure switch that detects low pressure inside the inflator and produces an appropriate diag
^
Since the passenger air bag module is much larger than the driver air bag module; it contains more gas genera
^ It is a component of the passenger air bag module and is not serviceable.
Air Bag
Theispassenger
constructed
air of ripstop nylon.
bag:^
^ 0.145 cubic meter (5.1 cubic feet)fills to a volume of approximately .
Reaction Housing
Thesupplies support
steel reaction for the inflator.
housing:^
^ provides a reaction surface for the passenger air bag module.
^ is used to attach the trim cover.
^ contains mounting brackets that attach the passenger air bag module to the instrument panel.
Trim Cover
is textured and painted to match the surface of the instrument panel.
^ isthermo-plastic
The constructed with
trima cover:^
moulded-in tear seam that separates when the air bag inflates and hinges out of the way d
^ retains the air bag in the reaction housing during vehicle operation.
^ is not a serviceable or repaintable item.
> Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal Procedures
Air Bag: Service and RepairAir Bag Disposal Procedures
Air Bag Disposal Recommendation

AIR BAG DISPOSAL RECOMMENDATIONS
Several situations may arise which require some form of disposal action: scrapping a vehicle containing a deployed a
Vehicle to be Scrapped; Live Air Bags
Electrically Deploy.
Vehicle to be Scrapped; Deployed Air Bags

Scrap Vehicle in the usual Manner.
Module Replaced; Damaged but Live Air Bags

Package and Label Properly. Return to Ford.
Module Replaced; Deployed Air Bags

Scrap Air Bags in the Usual Manner.
Air Bags, Deployed
To service a vehicle in which the air bag has deployed, the deployed air bag must be replaced with a new air bag modu
Air Bags, Undeployed - Faulty

NOTE:
All faulty live air bags have been placed on the Mandatory Return List. All discolored or damaged modules should be
In the event that an air bag is diagnosed as inoperative, the inoperative air bag must be replaced by a new air bag. The i
> Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal Procedures > Page 7940

warranty claim credit:
WARRANTY PARTS RETURN CENTER 7655 NORTH HAGGERTY ROAD CANTON, MI 48187-2435
The air bag must be packaged and shipped according to the U.S. Department of Transportation regulations. Retain pack
Scrapped Vehicle
Some vehicles that are damaged or inoperable to the point that service cannot be made may contain undeployed air bag
AIR BAG DISPOSAL
Air Bag Deployment, Remote
WARNING:^
CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FR
^
REMOTE DEPLOYMENT IS TO BE PERFORMED OUTDOORS WITH ALL PERSONNEL AT LEAS

^
DO NOT PLACE THE DRIVER OR PASSENGER AIR BAG MODULE WITH THE TRIM COVER FA
1. Remove the driver air bag module and passenger air bag module from the vehicle.
WARNING: CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POIN
25 mm (1 inch) 6 m (20 feet)2. Cut the two module connector wires and strip of insulation from the ends. Obtai
Connect one end of each wire to each of the air bag module wires.
vehicle battery.
10 minutes5. If successful, a loud report will be heard and the air bag material will be visible. Allow at least bef
allow for cooling.
6. The air bags are now deployed and can be scrapped in accordance with scrap metal procedures.
6 m (20 feet) 12-volt3. Place the air bag with the trim cover facing upward on a flat surface in a remote area such
Air Bag: Service and RepairAir Bag Replacement Registration Procedure
NOTE:
(VIN)
When replacing a driver air bag module or passenger air bag module, a prepaid return postcard is provided with the re
The various major assemblies in the driver air bag module and passenger air bag module have been designed to be tamp
CAUTION: Component assemblies may be removed and replaced when directed by the Diagnosis and Testing to avo
Information on proper handling and storage of air bag assemblies is provided.

Air Bag: Service and RepairRemoval and Installation
Driver's Side
REMOVAL
NOTE:
If the driver air bag module did not deploy in a collision, it may not have been needed. Complete all diagnostics befor
1. Record pre-set radio frequencies for reprogramming following completion of service procedures.
2. Disconnect battery ground cable.3. Wait one minute for backup power supply energy to be depleted.4. Remove the
WARNING^
INSTALLATION
NOTE: Fill out and return air bag traceability postcard for new air bag with VIN numbers and note diagnostic trouble
12 N.m (9 Lb-Ft)1. Connect the horn and air bag module electrical connectors to air bag sliding contact connectors.2

4. Prove out air bag system.5. Reprogram user 1 and user 2 radio frequencies and set clock.
Passenger's Side
REMOVAL
NOTE:
If the passenger air bag module did not deploy in a collision, it may not have been needed. Complete all diagnostics b

3. Remove instrument panel upper moulding.
4. Open glove compartment, press sides inward and lower glove compartment to floor.5. Through glove compartmen
pushing on passenger air bag module from inside panel. Do not handle passenger air bag module by grabbing edg
WARNING^
INSTALLATION
1. Connect electrical connector to passenger air bag module and position passenger air bag module in instrument pan
2.1-2.9 N.m (19-25 Lb-in)

7.6-10.4 N.m (68-92 Lb-in)2. Install two upper retaining screws. Tighten to .3. Install two lower module retaining bo

4. Return glove compartment to correct position.5. Install instrument panel upper moulding by snapping into place o
> Restraint Systems > Air Bag Systems > Air Bag Electronic Crash Sensor <--> [Air Bag Control Module] > Component Information > Specifications


> Restraint Systems > Air Bag Systems > Air Bag Electronic Crash Sensor <--> [Air Bag Control Module] > Component Information > Specifications > Page 7948



> Restraint Systems > Air Bag Systems > Air Bag Electronic Crash Sensor <--> [Air Bag Control Module] > Component Information > Description and Operation > Air Bag Electronic Cras

> Restraint Systems > Air Bag Systems > Air Bag Electronic Crash Sensor <--> [Air Bag Control Module] > Component Information > Description and Operation > Air Bag Electronic Cras
^ (ECS) six seconds
^ (LFCs) 30 seconds

(two second pause)
(five second pause)
(two second pause)
^ (NVRAM) (DTCs)
^

^
> Restraint Systems > Air Bag Systems > Air Bag Electronic Crash Sensor <--> [Air Bag Control Module] > Component Information > Service and Repair > Air Bag Electronic Crash Senso
REMOVAL
NOTE:
(ECS)
INSTALLATION

> Restraint Systems > Air Bag Systems > Air Bag Electronic Crash Sensor <--> [Air Bag Control Module] > Component Information > Service and Repair > Air Bag Electronic Crash Senso
Sensors (ECS)

Sensorbemodule
critical air bag
a vehicle eq
> Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls for Air Bag Deactivation Switch: > 98S20 > Aug >
Switch Durability Concern
SAFETY RECALL98920
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIII^

> Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls for Air Bag Deactivation Switch: >
98S20 > Aug > 98 > Recall - Airbag Deactivation Switch Durability Concern > Page 7965


LABOR ALLOWANCES

^ DOES II



> Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Deactivation S
Airbag Deactivation Switch Durability Concern
SAFETY RECALL98920
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIII^

> Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag
Deactivation Switch: > 98S20 > Aug > 98 > Recall - Airbag Deactivation Switch Durability Concern > Page 7975


LABOR ALLOWANCES

^ DOES II



> Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions
Clockspring Assembly / Spiral Cable: Service Precautions

WARNING:
-
ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAI
-
CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FR
- 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 HYDRO
-
NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR
- AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE REPLACED,
-
VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHI

-
TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP PO

NOTE:
Repair of the air-bag sliding contact (clock-spring) is made by REPLACEMENT only. If a part is replaced and the ne
> Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service Precautions > Page 7983
Clockspring Assembly / Spiral Cable: Description and Operation

The steering column has an air bag sliding contact to transfer electrical signals from the steering column to the steering
> Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Air Bag Sliding Contact
Clockspring Assembly / Spiral Cable: Service and RepairAir Bag Sliding Contact
REMOVAL
WARNING:
-
Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and w
-
Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduc
-
Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in
-
After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas gener
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can re
- Air bag modules with discolored or damaged trim covers must be installed new, not repainted.
-
Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air bag sup
-
To avoid accidental deployment and possible personal injury, the backup power supply must be depleted b
The side air bag sensors are located at or near the base of the B-pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one min
NOTE:
Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and
one minute.
1. Disconnect the battery ground cable and wait at least 2. Remove the driver air bag module.3. Remove the steering
NOTE: Make sure the wheels are in the straight-ahead position.
4. Apply two strips of masking tape across the air bag sliding contact to prevent accidental rotation when the air bag
5. Place the steering Column in the full down tilt position, then remove the tilt wheel handle and shank.
> Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Air Bag Sliding Contact > Page
7986

6. Remove the lower steering column cover.
1 Remove the two bolts.
2 Position the parking brake release aside.
3 Remove the lower steering column cover.
7. Remove the lower steering column reinforcement.

1 Remove the five bolts.
2 Remove the lower steering column reinforcement.
8. Remove the lower steering column shroud.
1 Remove the four screws.
2 Remove the lower steering column shroud.
7987

9. Remove the ignition switch lock cylinder.
1 Position the ignition switch lock cylinder to the RUN position.
2 Using a suitable tool, push upward on the cylinder release tab while pulling the ignition switch lock cylinder o
10. Remove the instrument panel lower insulator.
11. Loosen the forward steering column mounting nuts.
12. Disconnect the transmission range indicator cable.

13. Loosen the aft steering column mounting nuts and allow the steering column to drop down enough for clearance to
column shroud.
7988

14. Remove the upper steering column shroud.
(PATS)15. Remove the Passive Anti-theft System transmitter.

1 Remove the PATS transmitter retaining screw.
2 Remove the PATS transmitter.
16. Remove the key-in-ignition warning indicator switch.

17. Disconnect the air bag sliding contact electrical connectors.
1 Cut and remove the tie strap.
2 Separate the wires from the wiring harness retainer.
3 Remove the sliding contact electrical connectors from the wire connector bracket, then disconnect the connec
7989

18. Remove the air bag sliding contact.
1. Pry the air bag sliding contact retaining clips loose.2. Remove the air bag sliding contact.
INSTALLATION
WARNING:
-
Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and w
-
Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduc
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can re
NOTE:
Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and
1. Position and install the air bag sliding contact.

1 Install the air bag sliding contact on the steering column.
2 Make sure the retaining clips are engaged.
2. Connect the air bag sliding contact electrical connectors.
1 Connect the air bag sliding contact electrical connectors and install into the wire connector bracket.
2 Install the wires into the wiring harness retainer.
3 Install a new tie strap.
7990

3. Install the key-in-ignition warning indicator switch.
4. Install the passive anti-theft system (PATS) transmitter.

1 Position the PATS transmitter.
2 Install the PATS transmitter retaining screw.
5. Install the upper steering column shroud.

6. Install the ignition switch lock cylinder.
- Position the ignition switch lock cylinder to the RUN position.
- Insert the ignition switch lock cylinder into the steering column.
- Make sure the ignition switch lock cylinder is fully seated and aligned in the inter-locking washer before turni
- Make sure the ignition switch lock cylinder retaining pin is seated in the hole in the steering column.
- Rotate the ignition switch lock cylinder through all positions to verify operation.
7. Position the steering column up and hand-tighten the forward steering column mounting nuts.
7991

8. Connect the transmission range indicator cable.
9. Tighten the aft steering column mounting nuts.
10. Tighten the forward steering column mounting nuts.

7992

11. Install the lower steering column shroud.
1 Position the lower steering column shroud.
2 Install the four retaining screws.
12. Install the lower steering column reinforcement.

1 Position the lower steering column reinforcement.
2 Install the five bolts.
13. Install the lower steering column cover.
1 Position the lower steering column cover.
2 Position the parking brake release.
3 Install the two bolts.
7993

14. Install the tilt wheel handle and shank.
15. Remove the two strips of masking tape across the air bag sliding contact.16. Install the steering wheel.
NOTE: Make sure the wheels are in the straight-ahead position.
17. Install the driver air bag module.18. Prove out the air bag system.
> Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Air Bag Sliding Contact > Page 7994
Clockspring Assembly / Spiral Cable: Service and RepairService of Air Bag Equipped Vehicles Involved In Coll
If the collision involved deployment of driver air bag module or passenger air bag module, the steering column may ha
> Restraint Systems > Air Bag Systems > Diagnostic Connector, Air Bag > Component Information > Locations

The Air Bag Diagnostic Connector is located behind RH side of the instrument panel.
> Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications


> Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications > Page 8001

Engine View
> Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications > Page 8002

REMOVAL
INSTALLATION
> Restraint Systems > Air Bag Systems > Safing Sensor, Air Bag > Component Information > Locations

> Restraint Systems > Air Bag Systems > Safing Sensor, Air Bag > Component Information > Locations > Page 8006

> Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module
Side Air Bag: Service and RepairDriver Side Air Bag Module
REMOVAL
NOTE:
If the driver air bag module did not deploy in a collision, it may not have been needed. Complete all diagnostics befor
1. Record pre-set radio frequencies for reprogramming following completion of service procedures.
2. Disconnect battery ground cable.3. Wait one minute for backup power supply energy to be depleted.4. Remove the
WARNING^
INSTALLATION
12 N.m (9 Lb-Ft)1. Connect the horn and air bag module electrical connectors to air bag sliding contact connectors.2
3. Reconnect battery ground cable.4. Prove out air bag system.5. Reprogram user 1 and user 2 radio frequencies and
> Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module > Page 8011
Side Air Bag: Service and RepairPassenger Side Air Bag
REMOVAL
NOTE:
If the passenger air bag module did not deploy in a collision, it may not have been needed. Complete all diagnostics b

3. Remove instrument panel upper moulding.
4. Open glove compartment, press sides inward and lower glove compartment to floor.5. Through glove compartmen
pushing on passenger air bag module from inside panel. Do not handle passenger air bag module by grabbing edg
WARNING^
INSTALLATION
1. Connect electrical connector to passenger air bag module and position passenger air bag module in instrument pan
2.1-2.9 N.m (19-25 Lb-in)

7.6-10.4 N.m (68-92 Lb-in)
2. Install two upper retaining screws. Tighten to .3. Install two lower module retaining bolts. Tighten to .4. Return gl
> Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module > Page 8012

6. Reconnect battery ground cable.7. Prove out air bag system.8. Reprogram radio frequencies and set clock.
> 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 C
> Restraint Systems > Air Bag Systems > Standby Power Supply, Air Bag > Component Information > Service Precautions > Page 8016
Standby Power Supply: Description and Operation

Internal Backup Power Supply
^ (ECS)
one minuteThe Electronic Crash Sensor includes an internal backup power supply. This feature provides suffici

> Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Testing and Inspection
Malfunction Lamp / Indicator: Testing and Inspection

For testing procedures for this component, refer to Restraint Systems, Air Bag Systems, Testing and Inspection.
> Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Electronic Crash Sensor <--> [Air Bag Control Module] > Component Information > Specifications


> Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Electronic Crash Sensor <--> [Air Bag Control Module] > Component Information > Specifications > Page 8024

> Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Electronic Crash Sensor <--> [Air Bag Control Module] > Component Information > Specifications
> Page 8025

> Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Electronic Crash Sensor <--> [Air Bag Control Module] > Component Information > Specifications > Page 8026

> Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Electronic Crash Sensor <--> [Air Bag Control Module] > Component Information > Description and Operation > A
Module

> Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Electronic Crash Sensor <--> [Air Bag Control Module] > Component Information > Description and Operation > A
Module > Page 8029
^ (ECS) six seconds
^ (LFCs) 30 seconds

(two second pause)
(five second pause)
(two second pause)
^ (NVRAM) (DTCs)
^

^
> Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Electronic Crash Sensor <--> [Air Bag Control Module] > Component Information > Service and Repair > Air Bag
REMOVAL
NOTE:
(ECS)
INSTALLATION

> Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Electronic Crash Sensor <--> [Air Bag Control Module] > Component Information > Service and Repair > Air Bag
8032
Sensors (ECS)

Sensorbemodule
critical air bag
a vehicle eq
> Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming

WARNING:^
air bag module.
one minute (ECS)

WARNING:^
air bag module.

> Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 8038

> Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 8039

> Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation
Child Seat Tether Attachment: Description and Operation
WARNING: IT IS IMPORTANT THAT THE BOLT/ANCHOR BE SECURELY TIGHTENED TO SPECIFIC
If a child safety belt anchor tether is required for the child safety seat, a child safety belt anchor tether can be obtained f
> Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspe
Recall - Seat Belt Retractor Inspection/Replacement
SAFETY RECALL00S15
Certain 1996 through 2000 Model Year Crown Victoria, Grand Marquis & Town Car Vehicles Which Had the Left Fro
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIII^
^ Attachment IV
^ Lincoln Commitment Special Handling Procedure Announcement Letter

> Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S15 > Sep > 00 > Recall - Seat Belt
Retractor Inspection/Replacement > Page 8052


PLEASE NOTE
Correct all affected vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safe
PROMPTLY CORRECT
Promptly correct all affected vehicles on the VIN list provided in the Ford Dealership Consolidated Communicator (FD

Owners of affected vehicles according to Ford Motor Company records will be notified with the owner letter as shown.
NOTE:
Town Car owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Town Car
^ To claim for the "Lincoln Commitment Special Handling" on Town Car vehicles, follow the instructions of Atta
RENTAL CARS
If the safety belt requires replacement, Ford will pay for a loaner or rental vehicle except for fuel, which will be at the o
NOTE:
PARTS RETENTIONFollow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Proced

Town Car owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Town Car
LABOR ALLOWANCE

PARTS REQUIREMENTS
Parts Ordering InformationParts will not be direct shipped for this recall. Order your parts requirement through normal

Table 1 * # 150 * Crown Victoria/Grand Marquis
NOTE:
Please use the chart only until the next publication of the Service Parts Catalog (September, 2000).


Table 2 **150* Town Car
DEALER PRICEFor latest prices, refer to:
^ DOES II


LEFT FRONT SAFETY BELT RETRACTOR
OVERVIEWThis procedure will require the technician to locate and inspect the build label for the front left-hand seat b
LOCATING BUILD LABEL
NOTE:
The build label is located either on the seat belt webbing above the anchor boot or under the anchor boot.
1. Locate the build label on the webbing of the front left-hand seat belt retractor as follows:
^
Look for the build label on the webbing directly above the anchor boot. If the build label is located here proceed

^
Remove the anchor bolt cover, then the anchor bolt. Cut off the steel washer and remove the rubber washer to al
LABEL INSPECTION

1. Locate the build date code on the build label. Use the examples in Figure 4 and the Build Date Code Translator c
2. The affected seat belt retractors were built from 6/01/98 (23 198 R) through 5/21/00 (21700R) and must be replac
a.
If you have determined the seat belt must be replaced based on the build date, replace the seat belt retractor
NOTE:
Some of the safety belt retractors received from Ford Customer Service Division for the affected vehicles have been
b. If you have determined the seat belt does not need replacement, reassemble the retractor (if disassembly is
^ Using a length of mechanic's wire, pull the seat belt retractor anchor and webbing through the anchor boot.
^ Install the anchor bolt and rubber washer. Tighten the bolt to 40 Nm (30 lb-ft).
^ Install the anchor bolt cover.





> Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Rep
Recall - Seat Belt Inspection/Replacement
00S16SAFETY RECALL
Certain 1996 through 2000 Model Year Crown Victoria, Grand Marquis & Town Car Vehicles Which Had the Right F
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIII^
^ Attachment IV

Inspection/Replacement > Page 8071


PLEASE NOTE
PROMPTLY CORRECT

NOTE:
^ To claim for the "Lincoln Commitment Special Handling" on Town Car vehicles, follow the instructions on Atta
RENTAL CARS
NOTE:

LABOR ALLOWANCES

PARTS REQUIREMENTS
NOTE:



Table 2 * # 150 * Town Car
DEALER PRICEFor latest prices refer to:

^ DOES II

RIGHT FRONT SAFETY BELT RETRACTOR
OVERVIEWThis procedure will require the technician to locate and inspect the build label for the front right-hand sea

of two possible places on the seat belt webbing. Some minor disassembly may be required to access the build label. An
NOTE:
1. Locate the build label on the webbing of the front right-hand seat belt retractor as follows:
^

^
LABEL INSPECTION

a.
NOTE:






> Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > NHTSA00V157001 > Jun > 00 > Recall 00V157001:
Seat Belt: RecallsRecall 00V157001: Service Stock Seat Belt Assemblies
Vehicle Description: Passenger vehicles using aftermarket driver's seat belt assemblies that were sold by Ford Parts De
1996 FORD CROWN VICTORIA
1996 LINCOLN TOWN CAR
1996 MERCURY GRAND MARQUIS
> Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > NHTSA00V157002 > Jun > 00 > Recall 00V157002:
Seat Belt: RecallsRecall 00V157002: Service Stock Seat Belt Assemblies
Vehicle Description: Passenger vehicles using aftermarket front passenger side seat belt assemblies that were sold by F
> Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep > 00 > Recall - S
Replacement
SAFETY RECALL00S15
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIII^
^ Attachment IV

> Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S15 > Sep >
00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 8099


PLEASE NOTE
PROMPTLY CORRECT

NOTE:
RENTAL CARS
NOTE:

LABOR ALLOWANCE

PARTS REQUIREMENTS

NOTE:


^ DOES II


NOTE:
^

^
LABEL INSPECTION

a.
NOTE:





> Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 00S16 > Sep > 00 > Recall - S
00S16SAFETY RECALL
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIII^
^ Attachment IV

00 > Recall - Seat Belt Inspection/Replacement > Page 8118


PLEASE NOTE
PROMPTLY CORRECT

NOTE:
RENTAL CARS
NOTE:

LABOR ALLOWANCES

PARTS REQUIREMENTS
NOTE:




^ DOES II


NOTE:
^

^
LABEL INSPECTION

a.
NOTE:






> Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > NHTSA00V157001 > Jun > 0
Seat Belt Assemblies
Seat Belt: All Technical Service BulletinsRecall 00V157001: Service Stock Seat Belt Assemblies
Vehicle Description: Passenger vehicles using aftermarket driver's seat belt assemblies that were sold by Ford Parts De
> Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > NHTSA00V157002 > Jun > 0
Seat Belt Assemblies
Seat Belt: All Technical Service BulletinsRecall 00V157002: Service Stock Seat Belt Assemblies
Vehicle Description: Passenger vehicles using aftermarket front passenger side seat belt assemblies that were sold by F
> Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Page 8141
Seat Belt: Specifications

Description N.m (Lb-Ft)..................................................................................................................................................
34-46 (25-33)Front Safety Belt Anchor-to-Sill Bolt ...........................................................................................................
61-90 (45-66)Front Center Safety Belt Anchor Nut ............................................................................................................
34-46 (25-33)Front Safety Belt Guide Hex Flange Retaining Nut ......................................................................................
41-55 (31-40)Rear Safety Belt Anchor Nut .........................................................................................................................
41-55 (31-40)Rear Center Safety Belt Anchor Nut .............................................................................................................
41-55 (31-40)Rear Safety Belt Anchor-to-Rear Trim Panel Bolt ........................................................................................

> Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Page 8142
Seat Belt: Description and Operation
8 kph (5 mph)
While the vehicle is in motion, the combination lap and shoulder belt adjusts to the occupant's movement. However, if
> Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection
Seat Belt: Service and RepairCleaning and Inspection

WARNING: DO NOT BLEACH OR RE-DYE THE WEBBING AS WEBBING MAY WEAKEN.
Clean belt webbing only with a mild soap solution recommended for cleaning upholstery or carpets. Follow instructi
> Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 8145
Seat Belt: Service and RepairRemoval and Installation
Front Buckle End
REMOVAL
1. Remove front track end cover.2. Remove front center safety belt buckle end anchor nuts and washers (on LH side,
INSTALLATION

1. Slide front seat center passenger belts through slots in front seat.2. Connect safety belt buckle switch wire on LH s
61-90 N.m (45-66 Lb-Ft).
3. Check the restraint system for proper operation and perform Functional Test Procedure. See: Testing and Inspectio
General Diagnostics
Rear Seat Buckle End

REMOVAL
1. Remove rear seat cushion.2. Remove rear center safety bolt anchor nuts and rear safety belt and buckle.
INSTALLATION
41-55 N.m (31-40 Lb-Ft)
1. Install rear safety belt and buckle and rear center safety belt anchor nuts. Tighten nuts to .2. Install rear seat cushio
Diagnostics
Retractor and Tongue - Front Seats

SPECIAL SERVICE T00L(S) REQUIRED
Description
Tool Number ............................................................................................................................................................
REMOVAL
1. Remove front seat shoulder strap guide cover by gently pulling outward on the outer edges. Once released, lift upp
safety belt guide hex flange retaining nut.
NOTE: Safety Belt Bolt Bit 501-010 (T77L-2100-A) should be used for removal and installation of all safety be

2. Insert Safety Belt Bolt Bit 501-010 (T77L-2100-A) and remove the front safety belt guide hex flange retaining nut
INSTALLATION
34-46 N.m (25-33 Lb-Ft)
34-46 N.m (25-33 Lb-Ft)

1. Position front safety belt retractor and tongue in vehicle. Make sure safety belt webbing is not twisted. If it is, rem
shoulder strap guide cover over front safety belt guide and snap into position.
34-46 N.m (25-33 Lb-Ft)
7. Install front safety belt guide hex flange retaining nut. Tighten nut to .8. Gently push upper flap of front seat shoul
General Diagnostics
Retractor and Tongue - Rear Seats

REMOVAL
1. Remove rear seat cushion kit.2. Remove rear safety belt anchor nut.3. Remove roof side rear quarter trim panel.4.
INSTALLATION
34-46 N.m (25-33 Lb-Ft)1. Position rear safety belt retractor and tongue in vehicle. Make sure the safety belt webbi

3. Insert rear safety belt retractor and tongue through opening in the quarter trim panel. Snap rear safety belt opening
panel.
41-55 N.m (31-40 Lb-Ft)
4. Install rear safety belt anchor and rear safety belt anchor-to-trim panel bolts.5. Install roof side rear quarter trim pa
Diagnostics
Shoulder Strap Adjuster, Front Seat

REMOVAL
1. Dislodge upper flap of front seat shoulder strap guide cover by gently pulling outward on its outer edges. Once rel
reveal the front safety belt guide hex flange retaining nut.
2. Remove front seat shoulder strap guide cover by slipping finger behind it toward center of vehicle to dislodge from
front seat shoulder strap guide cover to remove.
INSTALLATION
1. Insert the front seat shoulder strap adjuster in the opening of the upper B-pillar structure. Make sure that front seat
the front seat strap adjuster is positioned above the front safety belt guide ring attachment stud. (The locator tab i
34-46 N.m (25-33 Lb-Ft)
2. Align both retaining bolts in the front seat strap adjuster to the weld nuts in the B-pillar reinforcement.3. Hand-sta
NOTE: Knob must be able to travel from top to bottom of slot in the B-pillar upper finish panel.
7. Position the front safety belt guide to the B-pillar. Position and hand-start the front safety belt guide hex flange ret
34-46 N.m (25-33 Lb-Ft)shoulder strap adjuster stud. Tighten to .
8. Check to see that the front safety belt guide rotates freely after installation.9. Gently push upper flap of front seat s
10. Position the front seat shoulder strap adjuster knob in the uppermost position.11. Check the restraint system for pr
General Diagnostics
Seat Belt: Service and RepairSafety Belt Maintenance and Inspection
WARNING: ALL SAFETY BELT ASSEMBLIES, INCLUDING RETRACTORS, BUCKLES, FRONT SEAT
Safety belt assemblies should be periodically inspected to make sure they have not become damaged and that they re
Before installing the new safety belt assembly, the safety belt attaching areas must be inspected for damage and disto
Install the new safety belts and then perform Functional Test Procedure. See: Testing and Inspection/Component Tes
Seat Belt: Service and RepairService Procedures
Post Collision Inspection
WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT B
7/16-inch x 20 TORX (R) 34-46 N.m (25-33 Lb-Ft)The seat and shoulder safety belts are factory-installed in their p
Before installing the new safety belt assembly, the safety belt attaching areas must be inspected for damage and disto
Install the new safety belt(s). Perform Functional Test Procedure. See: Testing and Inspection/Component Tests and
Seat Belt With Anchor Plate Thread Damage
7/16-inch x 20 TORX (R) 34-46 N.m (25-33 Lb-Ft)The seat and shoulder safety belts are factory-installed in their pro
27/64-inch 13/32-inch
1/2-13 tap
1. Remove broken or stripped bolt and discard.2. Drill out the internal threads in safety belt anchor plate with a drill
WARNING: EYE PROTECTION MUST BE WORN WHILE PERFORMING THIS PROCEDURE.
34-46 N.m (25-33 Lb-Ft)5. Install attachment parts in proper sequence. Tighten the replacement bolt to . Original pa
service parts indicated in the Parts Replacement Chart. See: Service and Repair/Parts Replacement Chart
34-466. When servicing a multiple belt and attachment, install nut to the bolt in the tunnel area from the underside of
N.m (25-33 Lb-Ft).
Seat Belt Without Anchor Plate Thread Damage
7/16-inch x 20 TORX (R) 34-46 N.m (25-33 Lb-Ft)The seat and shoulder safety belts are factory-installed in their pro
34-46 N.m (25-33 Lb-Ft)1. Remove damaged bolt from anchor reinforcement and discard.2. Install a new bolt by ha
Shoulder Strap Adjuster With Stripped Weld Nuts, Front Seat

1/2-inch1. With the B-pillar interior trim panel removed, drill out the damaged threads in the upper B-pillar structure
NOTE:
If the two hex-head attaching bolts on the shoulder safety belt height adjuster are not stripped, install the shoulde

M14 x 1.52. Apply a suitable lubricant to the threads of an tap and tap new threads.
3. Select a thread insert and hand-screw it into the retapped hole until it is slightly below the surface of the hole.
Afterêach rotation, back tap off slightly to remove new cuttings and be sure to blow out any chips before perf
NOTE:
^ The drive kees on the insert will act as an automatic stop.
12-ounce4. After installation of the thread insert, use a hammer to lightly tap an installation tool several times to dri
> Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Description and Operation
Seat Belt Buckle: Description and Operation
The inboard front safety belt buckle end is secured to the front safety belt buckle support. This allows the front safety b
> Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Buckle End - Rear Seats
Seat Belt Buckle: Service and RepairBuckle End - Rear Seats

REMOVAL
1. Remove rear seat cushion.2. Remove rear center safety bolt anchor nuts and rear safety belt and buckle.
INSTALLATION
41-55 N.m (31-40 Lb-Ft)
1. Install rear safety belt and buckle and rear center safety belt anchor nuts. Tighten nuts to .2. Install rear seat cushio
Diagnostics
> Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Buckle End - Rear Seats > Page 8157
Seat Belt Buckle: Service and RepairBuckle End - Front Seats
REMOVAL
1. Remove front track end cover.2. Remove front center safety belt buckle end anchor nuts and washers (on LH side,
INSTALLATION
1. Slide front seat center passenger belts through slots in front seat.2. Connect safety belt buckle switch wire on LH s
61-90 N.m (45-66 Lb-Ft).
> Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Buckle End - Rear Seats > Page 8158

3. Check the restraint system for proper operation and perform Functional Test Procedure. See: Testing and Inspectio
General Diagnostics
> Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Description and Operation
Seat Belt Extension: Description and Operation
20 cm (8 inches)
A safety belt that is too short even when fully extended can be lengthened. The safety belt extension is available. This a
> Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Specifications
Seat Belt Height Adjuster: Specifications

Description N.m (Lb-Ft)..................................................................................................................................................
34-46 (25-33)Front Seat Shoulder Strap Adjuster Bolt .......................................................................................................

> Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Specifications > Page 8165
Seat Belt Height Adjuster: Service and Repair

REMOVAL
1. Dislodge upper flap of front seat shoulder strap guide cover by gently pulling outward on its outer edges. Once rel
reveal the front safety belt guide hex flange retaining nut.
2. Remove front seat shoulder strap guide cover by slipping finger behind it toward center of vehicle to dislodge from
front seat shoulder strap guide cover to remove.
INSTALLATION
1. Insert the front seat shoulder strap adjuster in the opening of the upper B-pillar structure. Make sure that front seat
the front seat strap adjuster is positioned above the front safety belt guide ring attachment stud. (The locator tab i
34-46 N.m (25-33 Lb-Ft)
2. Align both retaining bolts in the front seat strap adjuster to the weld nuts in the B-pillar reinforcement.3. Hand-sta
NOTE: Knob must be able to travel from top to bottom of slot in the B-pillar upper finish panel.
7. Position the front safety belt guide to the B-pillar. Position and hand-start the front safety belt guide hex flange ret
34-46 N.m (25-33 Lb-Ft)shoulder strap adjuster stud. Tighten to .
8. Check to see that the front safety belt guide rotates freely after installation.9. Gently push upper flap of front seat s
10. Position the front seat shoulder strap adjuster knob in the uppermost position.11. Check the restraint system for pr
General Diagnostics
> Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspectio
SAFETY RECALL00S15
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIII^
^ Attachment IV

> Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S15 > Sep > 00 > Recall - Seat Belt


PLEASE NOTE
PROMPTLY CORRECT

NOTE:
RENTAL CARS
NOTE:

LABOR ALLOWANCE

PARTS REQUIREMENTS

NOTE:


^ DOES II


NOTE:
^

^
LABEL INSPECTION

a.
NOTE:





> Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replace
00S16SAFETY RECALL
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIII^
^ Attachment IV



PLEASE NOTE
PROMPTLY CORRECT

NOTE:
RENTAL CARS
NOTE:

LABOR ALLOWANCES

PARTS REQUIREMENTS
NOTE:




^ DOES II


NOTE:
^

^
LABEL INSPECTION

a.
NOTE:






> Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-9-7 > May > 02 > Turn Signa
Article No.02-9-7
05/13/02
SERVICE PROCEDURE
1
3.
> Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-9-7 > May >
02 > Turn Signals - Intermittent Rapid Flashing > Page 8213


SUPERSEDES: 01-21-3
DEALER CODING
CONDITION
BASIC PART NO. CODE
> Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-9-7 > May >
02 > Turn Signals - Intermittent Rapid Flashing > Page 8214

13C788 42
OASIS CODES: 201000, 201100, 201200, 206000

> Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 02-9-7 > May
> 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement
SAFETY RECALL00S15
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIII^
^ Attachment IV

> Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: >
02-9-7 > May > 02 > Recalls for Seat Belt Retractor: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 8224


PLEASE NOTE
PROMPTLY CORRECT

NOTE:
RENTAL CARS
NOTE:

LABOR ALLOWANCE

PARTS REQUIREMENTS

NOTE:


^ DOES II


NOTE:
^

^
LABEL INSPECTION

a.
NOTE:





> Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Retractor: > 02-9-7 > May
> 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement
00S16SAFETY RECALL
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIII^
^ Attachment IV

02-9-7 > May > 02 > Recalls for Seat Belt Retractor: > 00S16 > Sep > 00 > Recall - Seat Belt Inspection/Replacement > Page 8243


PLEASE NOTE
PROMPTLY CORRECT

NOTE:
RENTAL CARS
NOTE:

LABOR ALLOWANCES

PARTS REQUIREMENTS
NOTE:




^ DOES II


NOTE:
^

^
LABEL INSPECTION

a.
NOTE:






> Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Exterior Lighting Module: > 00S15
Retractor Inspection/Replacement
SAFETY RECALL00S15
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIII^
^ Attachment IV

> Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Exterior Lighting
Module: > 00S15 > Sep > 00 > Recall - Seat Belt Retractor Inspection/Replacement > Page 8263


PLEASE NOTE
PROMPTLY CORRECT

NOTE:
RENTAL CARS
NOTE:

LABOR ALLOWANCE

PARTS REQUIREMENTS

NOTE:


^ DOES II


NOTE:
^

^
LABEL INSPECTION

a.
NOTE:





> Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Exterior Lighting Module: > 00S16
Bulletins for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing
Article No.02-9-7
05/13/02
SERVICE PROCEDURE
1
3.
Module: > 00S16 > Sep > 00 > All Technical Service Bulletins for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing > Page 8286


SUPERSEDES: 01-21-3
DEALER CODING
CONDITION
BASIC PART NO. CODE
Module: > 00S16 > Sep > 00 > All Technical Service Bulletins for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing > Page 8287

13C788 42
OASIS CODES: 201000, 201100, 201200, 206000

> Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Page 8288
> Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Page 8289
REMOVAL
INSTALLATION
> Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Component Information > Locations > Compressor Relay (Level Control)

Engine View
> Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Component Information > Locations > Compressor Relay (Level Control) >

> Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Component Information > Locations > Page 8295
> Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Component Information > Locations > Page 8296
REMOVAL
INSTALLATION
> Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Component Information > Testing and Inspection > Differential Axle Housin
Differential Axle Housing: Testing and InspectionDifferential Axle Housing
Casting Porosity (Holes In Casting)
Rear axle lubricant may leak through small pockets in the material of the axle housing casting. These pockets (castin
manufacturing standard M3D35-A(E).
Weld Leaks
Most minor weld leaks can be corrected with epoxy sealer meeting Ford manufacturing standard M3D35-A(E). This
> Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Component Information > Testing and Inspection > Differential Axle Housin
Differential Axle Housing: Testing and InspectionDifferential/Axle Housing Vent

NOTE:
If rear axle housing vent cannot be cleared, it must be replaced using Stud and Bearing Mount EOAZ-19554-BA o
A plugged rear axle housing vent will cause excessive seal lip wear due to internal pressure buildup. When a leak oc
Make sure axle lubricant is level with bottom of fill hole.
> Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Component Information > Service and Repair > Differential/Axle Housing V
Differential Axle Housing: Service and RepairDifferential/Axle Housing Vent

REMOVAL
2. Remove rear axle housing vent from rear axle housing.
INSTALLATION
1. Install rear axle housing vent into rear axle housing.2. Lower vehicle.
> Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Component Information > Service and Repair > Differential/Axle Housing V
Differential Axle Housing: Service and RepairDifferential Axle Housing
REMOVAL
1. Raise the vehicle on a hoist, and position safety stands under the rear frame crossmember.
WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF
2. Remove the wheel and tire assemblies.
3. Remove the rear disc brake caliper.
NOTE: Position the rear disc brake caliper forward of the axle, and support it with a length of wire.
4. Remove the rear disc brake rotor

5. Disconnect the parking brake rear cable and conduits from the parking brake lever.6. Disconnect the parking brake
cable and lift the inner cable through the slot. Position the parking brake rear cable and conduits out of the way.
> Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Component Information > Service and Repair > Differential/
Axle Housing Vent > Page 8304

NOTE: Relieve the tension of the parking brake rear cable and conduits.
7. Remove the rear brake anti-lock sensors. Release the clips on the axle housing, and position the sensors aside.
8. Disconnect the rear stabilizer bar from the rear stabilizer bar link and bushing.
9. Remove the rear stabilizer bar bracket bolts, the rear stabilizer bar bracket and the rear stabilizer bar.

10. Disconnect the air suspension height sensor from the watts linkage arm.11. Mark and remove the driveshaft.
12. Remove the watts linkage retaining nut.
13. Separate the watts linkage from the axle housing.

14. Support the rear axle assembly with a Rotunda High-Lift Transmission Jack 164-R3508 or equivalent.

15. Remove the shock absorber lower nuts, and separate the rear shock absorber from the mountings on the axle housi
16. Remove the rear suspension lower arm nuts and bolts.
17. Remove the rear suspension upper arm nuts and bolts.18. Unseat the rear springs from the axle housing.
19. Lower the axle, and remove it from the vehicle.
INSTALLATION

1. Transfer all the components from the old rear axle housing to the new rear axle housing, and make the necessary a
preload.
2. Install new rear wheel bearings into the new rear axle housing using Axle Tube Bearing Replacer 205-124 (T78P-
3. Install a new inner wheel bearing oil seal using Axle Tube Seal Replacer 205-123 (T78P-1177-A). Apply Premium
X or equivalent meeting Ford specification ESA-M1C75-B between the lips of the inner wheel bearing oil seal.
4. Position the rear axle assembly under the vehicle and raise the axle with Rotunda High-Lift Transmission Jack 164
87 - 1196. Position the rear suspension upper arms into the brackets, and install the nuts and the bolts. Tighten the re
Nm (64 - 87 ft. lbs.).

127 -7. Position the rear suspension lower arms into the brackets, and install the nuts and the bolts. Tighten the rear s
173 Nm (94 - 128 ft. lbs.).
76 - 103 Nm (57 - 75 ft. lbs.).8. Install the rear shock absorber in the shock absorber mounting bracket. Tighten the s
212 - 288 Nm (157 - 212 ft. lbs.).9. Install the wafts linkage onto the bellcrank stud. Tighten the watts linkage retain

10. Connect the air suspension height sensor to the watts linkage arm.
21 - 29 Nm (16 - 21 ft. lbs.).

11. Install the rear stabilizer bar and the rear stabilizer bar brackets. Tighten the rear stabilizer bar bracket bolts to 12.
17 - 23 Nm (13 - 16 ft. lbs.).13. Connect the rear stabilizer bar link and bushing to the rear stabilizer bar. Tighten the

5 - 6 Nm (45 -14. Reposition the brake anti-lock sensor wires, and install the rear brake anti-lock sensors. Tighten the
53 inch lbs.).
15. Reposition the parking brake rear cable and conduits. Connect the parking brake rear cable and conduits to the rea
and install the retaining clip.
16. Connect the parking brake rear cable and conduits to the parking brake lever.
NOTE: Restore the tension to the parking brake rear cable and conduit.
115 - 142 Nm (85 - 105 ft. lbs.).
118 ml (4 oz)17. Install the rear disc brake rotor.18. Install the rear disc brake caliper.18. Install the wheel and tire ass
6 - 14 mm (1/4- 9/16 inch)
20 - 40 Nm (15 - 30 ft.lbs.). Additive Friction Modifier C8AZ- 1 913546-A or equivalent meeting Ford specifica
> Restraint Systems > Seat Belt Systems > Seat Belt Warning Timer > Component Information > Description and Operation
Seat Belt Warning Timer: Description and Operation

The safety belt warning indicator lamp illuminates and a chime sounds to remind the occupants to fasten their safety be
The conditions of operation for the safety belt warning indicator lamp and chime are as follows:
^
1-2minutes 4-8 secondsIf the driver's safety belt is not buckled before the ignition switch is turned to RUN, then
^
If the driver's safety belt is buckled while the safety belt warning indicator lamp is illuminated and the reminder c
^
If the driver's safety belt is buckled before the ignition switch is turned to RUN then the safety belt warning indic
> Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls: > 98S20 > Aug > 98 > Re
Durability Concern
SAFETY RECALL98920
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIII^

> Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls: > 98S20 >
Aug > 98 > Recall - Airbag Deactivation Switch Durability Concern > Page 8323


LABOR ALLOWANCES

^ DOES II



> Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air
> Nov > 98 > Recalls for Air Bag Deactivation Switch: > 98S20 > Aug > 98 > Recall - Airbag Deactivation Switch Durability Concern
SAFETY RECALL98920
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
TechnicalIII^

> Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Air Bag Deactivation Switch: > 98-23-10 > Nov > 98 > Recalls for Air Bag Deactivation Switch: > 98S20 > Aug > 98 > Recall - Airbag Deactivation Switch
Durability Concern > Page 8337


LABOR ALLOWANCES

^ DOES II



> Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air
8342

> Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications


> Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 8346

Engine View
> Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications > Page 8347

REMOVAL
INSTALLATION
> Restraint Systems > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Locations

> Restraint Systems > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Locations > Page 8351

> Accessories and Optional Equipment > Antenna > Antenna Amplifier > Component Information > Locations
Antenna Amplifier: Locations

Full Body View
The Hidden Antenna Module is located at the RH front of trunk.

> Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Passive Anti-Theft System Module

> Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Passive Anti-Theft System Module > P

> Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module

> Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module > Page 8

> Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 8366

Removal
junction panel.
PATS Control Module
Installation
Note:
> Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transceiver <--> [Alarm System Transponder] > Component Information > Service and Repair
Alarm System Transceiver: Service and Repair

Removal
1. Remove ignition switch lock cylinder from steering column housing. 2. Remove both upper and lower steering col
Note: Only apply pressure or leverage below the key cylinder lower rib.
4. Locate rib on steering column lock cylinder housing. Use a small screwdriver to gently pry PATS transceiver mod
PATS Transceiver
Installation
1. Locate post on circular antenna and align to open slot of steering column key cylinder barrel. 2. Apply even pressu
Note: Avoid pinching the transceiver wires with the retaining screw.
2 Nm (18 lb-in).
4. Install PATS transceiver module retaining screw to steering column lock cylinder housing. Tighten to 5. Connect P
Note: No key replacement or re-initialization needs to occur with the removal or installation of a new PATS tran
8. Check the system for normal operation.
> Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Diagrams
Remote Keyless Entry Switch Assembly

> Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Diagrams > Page 8374
Keyless Entry Key-Pad: Description and Operation

CAUTION: Do not use a key, pencil or any other hard object to press the keyless entry keypad buttons. These objects
- To unlock the driver door enter the permanent factory code or enter the owner's alternate code (if programmed).
- five secondsTo unlock the passenger door(s), press the 3/4 button within of unlocking the driver door or luggage
- five secondsTo unlock the luggage compartment door, press the 5/6 button within of unlocking driver or passeng
-
To turn on the courtesy lamps and light all illuminated components, lift either front door handle (only if not equip
-
To lock all doors, press the 7/8 and 9/0 buttons at the same time with all doors closed. (It is not necessary to enter
To program an alternate keyless entry keypad code:
five seconds
1. Enter the five digit permanent entry code into keyless entry keypad.2. Within of pressing last button of permanent
> Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Diagrams > Page 8375
Keyless Entry Key-Pad: Service and Repair

REMOVAL
1. Disconnect battery ground cable.2. Remove front door trim panel.3. Disconnect door lock switch actuator wiring h
INSTALLATION
> Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Driver's Door Module <--> [Keyless Entry Module] > Component Information > Service and Repai

REMOVAL
INSTALLATION
> Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service
Keyless Entry Transmitter Battery: Service and Repair
REMOVAL
1. Twist a thin coin between the two halves of the keyless entry remote transmitter.
CAUTION: Do not take the front half of the transmitter apart.
NOTE:
The keyless entry remote transmitter is powered by one coin-type, three-volt lithium batteries. Install new batter
2. Carefully swing the contacts off the battery and remove the old battery.
INSTALLATION
1. Carefully swing the contacts back onto the top of the battery.2. Snap the two halves of the transmitter back togethe
> Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams
Message Center Switch Assembly

> Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service and Repair
Amplifier: Service and Repair

REMOVAL
1. Disconnect electrical connector from subwoofer radio amplifier.2. Remove four retaining screws and radio amplif
INSTALLATION
> Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams
CD Changer (499)
> Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer I
01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers
Radio/Stereo Noise Filter: Customer InterestFuel Pump - Whine Heard Through Radio Speakers
Article No.01-7-3
04/16/01
FUEL SYSTEM - FUEL PUMP"WHINING"/"BUZZING" NOISE COMES THROUGHENTERTAINMENT OR
RADIO - ENTERTAINMENT OR TWO - WAYCOMMUNICATION - "WHINING"/"BUZZING" NOISEIN SPE
NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY
FORD:1990-1994TEMPO
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
MARK VII
1990-1999 CONTINENTAL
1990-2001 TOWN CAR
1997-1998 MARK VIII
1998-2001 NAVIGATOR
TOPAZ
MERCURY:1990-1994
1990-1997 COUGAR
1990-1999 SABLE
1990-2001 GRAND MARQUIS
1991-1999 TRACER
1997-1999 MYSTIQUE
1999
2001 COUGAR
SABLE
1993-2001 VILLAGER
LINCOLN:1990-1992
1997-2001 MOUNTAINEER
This TSB article is being republished in its entirety to update the model year vehicles.
ISSUE
ACTION
> 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 8403

NOTE
NOTE
TEST PROCEDURE
1.
3.
SERVICE PROCEDURE

c.
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS

TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CON
NOTE
WARNING

3.
a.
NOTE:

NOTE:
WARNING
CAUTION
6.
Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for th
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, 91-17-5SUPERSEDES: 99-12-9WARRANTY STATUS: Eligible Unde



OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 205000, 207000, 404000, 702000, 702300

> Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technic
Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers
Radio/Stereo Noise Filter: All Technical Service BulletinsFuel Pump - Whine Heard Through Radio Speakers
Article No.01-7-3
04/16/01
FORD:1990-1994TEMPO
1997-1999 CONTOUR
2001 TAURUS
1990 BRONCO II
1990-1996 BRONCO
1990-1999 F-250 LD
1991-2001 EXPLORER
1995-2001 WINDSTAR
2000-2001 EXCURSION
2001 ESCAPE
MARK VII
1990-2001 TOWN CAR
1997-1998 MARK VIII
1998-2001 NAVIGATOR
TOPAZ
MERCURY:1990-1994
1990-1997 COUGAR
1990-1999 SABLE
1991-1999 TRACER
1997-1999 MYSTIQUE
1999
2001 COUGAR
SABLE
1993-2001 VILLAGER
LINCOLN:1990-1992
ISSUE
ACTION
Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8415

NOTE
NOTE
TEST PROCEDURE
1.
3.
SERVICE PROCEDURE

c.
NOTE

NOTE
WARNING

3.
a.
NOTE:

NOTE:
WARNING
CAUTION
6.
PARTS BLOCK



DEALER CODING
OASIS CODES: 205000, 207000, 404000, 702000, 702300

> Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Missing or Damage
Radio/Stereo Noise Filter: Service and RepairMissing or Damaged Noise Suppression Components
- Noise suppression components may be damaged or missing.
-
Check radio frequency interference suppression grounding effectiveness by wedging a large file between metal p
-
Listen for a decrease in the objectionable radio chassis noise. If a reduction in noise is noted, first try tightening b
> Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Missing or Damage
Page 8424
Radio/Stereo Noise Filter: Service and RepairRemoval and Installation
Radio Frequency Interference Suppression Bond

REMOVAL
1. Remove screw from cowl panel.2. Remove nut from engine.3. Remove wire from fuel rail ground.4. Remove radi
INSTALLATION
2.0-2.5 N.m (18-22 Lb-In)2. Tighten screw to .
Radio Ignition Interference Capacitor
> Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair >
Missing or Damaged Noise Suppression Components > Page 8425

REMOVAL
NOTE: There is a radio ignition interference capacitor mounted on rear of LH cylinder head.
2. Remove retaining bolt and remove radio ignition interference capacitor.
INSTALLATION
> Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > A
Through Radio Speakers
Speaker: Customer InterestFuel Pump - Whine Heard Through Radio Speakers
Article No.01-7-3
04/16/01
FORD:1990-1994TEMPO
1997-1999 CONTOUR
2001 TAURUS
1990 BRONCO II
1990-1996 BRONCO
1990-1999 F-250 LD
1991-2001 EXPLORER
1995-2001 WINDSTAR
2000-2001 EXCURSION
2001 ESCAPE
MARK VII
1990-2001 TOWN CAR
1997-1998 MARK VIII
1998-2001 NAVIGATOR
TOPAZ
MERCURY:1990-1994
1990-1997 COUGAR
1990-1999 SABLE
1991-1999 TRACER
1997-1999 MYSTIQUE
1999
2001 COUGAR
SABLE
1993-2001 VILLAGER
LINCOLN:1990-1992
ISSUE
ACTION
> 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 8434

NOTE
NOTE
TEST PROCEDURE
1.
3.
SERVICE PROCEDURE

c.
NOTE

NOTE
WARNING

3.
a.
NOTE:

NOTE:
WARNING
CAUTION
6.
PARTS BLOCK



DEALER CODING
OASIS CODES: 205000, 207000, 404000, 702000, 702300

> Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker:
Whine Heard Through Radio Speakers
Speaker: All Technical Service BulletinsFuel Pump - Whine Heard Through Radio Speakers
Article No.01-7-3
04/16/01
FORD:1990-1994TEMPO
1997-1999 CONTOUR
2001 TAURUS
1990 BRONCO II
1990-1996 BRONCO
1990-1999 F-250 LD
1991-2001 EXPLORER
1995-2001 WINDSTAR
2000-2001 EXCURSION
2001 ESCAPE
MARK VII
1990-2001 TOWN CAR
1997-1998 MARK VIII
1998-2001 NAVIGATOR
TOPAZ
MERCURY:1990-1994
1990-1997 COUGAR
1990-1999 SABLE
1991-1999 TRACER
1997-1999 MYSTIQUE
1999
2001 COUGAR
SABLE
1993-2001 VILLAGER
LINCOLN:1990-1992
ISSUE
ACTION
> 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 8446

NOTE
NOTE
TEST PROCEDURE
1.
3.
SERVICE PROCEDURE

c.
NOTE

NOTE
WARNING

3.
a.
NOTE:

NOTE:
WARNING
CAUTION
6.
PARTS BLOCK



DEALER CODING
OASIS CODES: 205000, 207000, 404000, 702000, 702300

> Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 8453
Speaker: Specifications
Bracket Assembly Nut .........................................................................................................................................................
> Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 8454
Speaker: Description and Operation

- Some vehicles are equipped with luxury radio speakers.
- Some vehicles may be equipped with JBL (R) radio speakers. These speakers have "Ford/JBL (R) Audio System
-
JBL (R) radio speakers and luxury sound radio speakers are not interchangeable. However, the JBL (R) radio spe
- The JBL (R) system has a subwoofer radio speaker. The subwoofer is mounted on the rear deck between the rear
> Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door
Speaker: Service and RepairFront Door

REMOVAL
1. Remove lower door panel.2. Remove four screws retaining radio speaker to door.3. Pull radio speaker away from
INSTALLATION
1. Firmly push the radio speaker lead into radio speaker connector.2. Position radio speaker to door and install four r
> Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door > Page 8457
Speaker: Service and RepairQuarter Trim Panel Speakers

REMOVAL
1. Remove package tray panel.2. Remove four radio speaker retaining screws.3. Disconnect connector and lift out ra
INSTALLATION
1. Install radio rear seat speaker cover, if removed.
NOTE: Radio rear seat speaker cover is not used with JBL (R) radio speaker.
2. Make speaker connection and position radio speaker from top side of rear window tray. JBL (R) radio speaker enc
that connectors face outboard in vehicle.
NOTE:
If connection of radio speaker is difficult to reach from top side of rear window tray, the connection may be acc
3. Install four retaining screws.4. Install package tray panel.

> Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door > Page 8458
Speaker: Service and RepairRadio Speakers, Subwoofer Enclosure, JBL (R)

REMOVAL
1. Remove spare tire.
INSTALLATION
7-9 N.m (62-79 Lb-In)1. Follow removal procedure in reverse order.2. Tighten nuts to .
2. Remove four nut and washer assemblies from bottom of subwoofer. Remove subwoofer by lowering straight down
> Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Service and Repair
Tape Player: Service and Repair
The playback head, capstans and pinch rollers may accumulate an oxide residue from the cassette tape while playing. D
CAUTION: Oxide accumulation can cause weak or wavering sound and damage to the cassette tape and tape pl
10-12 hours
It is recommended for best performance that the cassette tape player be cleaned after every of playing time with a cass
CAUTION: The use of other cassette cleaners is not recommended. Damage to the cassette player could result.
> Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Passive A

> Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Passive A
8467

> Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-The

> Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-The

> Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 847

Removal
junction panel.
PATS Control Module
Installation
Note:
and Repair
> Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Driver's Door Module <--> [Keyless Entry Module] > Component Information > Serv

REMOVAL
INSTALLATION
> Body and Frame > Cabin Ventilation Grille > Component Information > Technical Service Bulletins > Customer Interest for Cabin Ventilation Grille: > 99-4-5 > Mar > 99 > Right Hand W
Cabin Ventilation Grille: Customer InterestRight Hand Windshield - Buzzing/Whistling Noise
Article No.99-4-5
03/08/99
SERVICE PROCEDURE
3.
4.

Warranty Coverage

Screen Repair
DEALER CODING
CONDITION
BASIC PART NO. CODE
> Body and Frame > Cabin Ventilation Grille > Component Information > Technical Service Bulletins > Customer Interest for Cabin Ventilation Grille: > 99-4-5 > Mar > 99 >
Right Hand Windshield - Buzzing/Whistling Noise > Page 8484

54018A16 12
OASIS CODES: 108000, 208000, 208300, 208999, 701000, 702000, 702100, 702300
> Body and Frame > Cabin Ventilation Grille > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cabin Ventilation Grille: > 99-4-5 > Mar > 99 >
Whistling Noise
Cabin Ventilation Grille: All Technical Service BulletinsRight Hand Windshield - Buzzing/Whistling Noise
Article No.99-4-5
03/08/99
SERVICE PROCEDURE
3.
4.

Warranty Coverage

Screen Repair
DEALER CODING
CONDITION
BASIC PART NO. CODE
> Body and Frame > Cabin Ventilation Grille > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cabin Ventilation Grille: > 99-4-5
> Mar > 99 > Right Hand Windshield - Buzzing/Whistling Noise > Page 8490

54018A16 12
OASIS CODES: 108000, 208000, 208300, 208999, 701000, 702000, 702100, 702300
> Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 99-4-5 > Mar > 99 > Right Hand Windshield - Buzzing/Whistling Noise
Cowl: Customer InterestRight Hand Windshield - Buzzing/Whistling Noise
Article No.99-4-5
03/08/99
SERVICE PROCEDURE
3.
4.

Warranty Coverage

Screen Repair
DEALER CODING
CONDITION
BASIC PART NO. CODE
> Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 99-4-5 > Mar > 99 > Right Hand Windshield - Buzzing/
Whistling Noise > Page 8499

54018A16 12
OASIS CODES: 108000, 208000, 208300, 208999, 701000, 702000, 702100, 702300
> Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 99-4-5 > Mar > 99 > Right Hand Windshield - Buzzing/Wh
Cowl: All Technical Service BulletinsRight Hand Windshield - Buzzing/Whistling Noise
Article No.99-4-5
03/08/99
SERVICE PROCEDURE
3.
4.

Warranty Coverage

Screen Repair
DEALER CODING
CONDITION
BASIC PART NO. CODE
> Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 99-4-5 > Mar > 99 > Right Hand
Windshield - Buzzing/Whistling Noise > Page 8505

54018A16 12
OASIS CODES: 108000, 208000, 208300, 208999, 701000, 702000, 702100, 702300
> 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

Handle, Outside Door
Removal
NOTE: This procedure applies to front and rear.
1. Remove door trim panel and watershield.
2. Disconnect the door latch actuator rod from the latch.
3. Remove the two rivets retaining the door handle (22404) or rear door outside handle (26604) to the door. Remove
outside handle and rod from the door.
4. Transfer the actuator rod to the new door handle or rear door outside handle
Installation
1. Follow removal procedure in reverse order. Use Heavy Duty Riveter 501-Doll (D80L-23200-A) or equivalent.
> 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 BulletinsInterior 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, THUNDERBIRD1995-1999 CONTOUR, CROWN VICTORIA, MUSTANG1996-1999 E
LINCOLN-MERCURY:1993-1998 MARK VIII1995-1997 COUGAR1995-1999 CONTINENTAL, GRAND MARQU
LIGHT TRUCK:1993-1996 BRONCO1993-1997 F SUPER DUTY, F-250 HD, F-3501993-1999 F-150, F-250 LD199
ISSUEThere has been an increase in the number of door trim panel replacements due to damage. This may be caused b
ACTIONReview the appropriate model/year Service/Workshop Manual, Section 01-05/501-05 prior to removing the d
> 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 8517

For a door trim panel with "molded hook" design, Figure 1 displays the correct direction of force applied during the do
WARNING
REMOVE ALL THE SCREWS AND TWO-STAGE PINS BEFORE ATTEMPTING TO REMOVE TRIM PANE
Detailed instructions and illustration can be found in the appropriate model/year Service/Workshop Manual, Section 01
> Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel -

WARRANTY STATUS: INFORMATION ONLYOASIS CODES: 102000, 107000,112000,190000
> Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Page 8519
Front Door Panel: Service and Repair
Door Panel R&R

> Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Page 8520

Door Panel R&R
Removal
1. Remove window regulator control switch housing by gently prying up, starting at the front.
2. Disconnect all connectors from window regulator control switch housing.
3. Remove inside door handle cup by gently prying at screwdriver slot with a screwdriver.
4. Remove screw directly beneath inside door handle.
5. Remove lower screw retaining front door trim panel to door inner panel.
6. Lift front door trim panel upward and snap out trim panel.
7. Disconnect wire harnesses from door panel as required and remove front door trim panel.
Installation
1. Connect wire harnesses to front door trim panel as required.
2. Install front door trim panel by pushing in and down until it snaps into place.
3. Install all self-tapping screws retaining front door trim panel to door inner panel.
4. Install inside door handle cup.
5. Install window regulator control switch housing.

> 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
Front Glass
REMOVAL
1. Remove front door trim panel and front door trim shield.2. Loosen front door glass run front retainer retaining scre
1/4-inchpunch. Using a diameter drill, drill out remainder of rivets.
CAUTION: Do not attempt to pry out the rivets as damage to the front door window glass will result.
NOTE:
Prior to removing the rivet center pins, it is necessary to place a suitable block support between the door outer p
4. Remove front door window glass.
INSTALLATION
1/4-inch 1/4-20 x 1-inch1. Insert front door window glass into front door between front door belt line outside weathe
1/4-inch 9-14 N.m (80-124 Lb-In)
assemblies and -20 nut and washer assemblies is optional). Tighten nut (if used) to . Do not exceed maximumtorq
4. Tighten front door glass run front retainer retaining screw.5. Adjust front door window glass.6. Install front door t
> 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

REMOVAL
1. If front door window glass is in the down position and is inoperable, the following steps must be taken; if front do
go to Step 2.a. Remove front door trim panel and front door trim shield.b. Disconnect battery ground cable.c. Dis
CAUTION: Be careful not to strike or scratch front door window glass because it can break.
Raise front
e. Remove door regulator
window window glass to full
electric upfrom
drive position
frontbydoor
hand and secure
power windowwith tape.
regulator.f.
g. Go to Step 5.
1/4-inch2. Remove front door trim panel and front door trim shield.3. Remove front door window glass.4. Disconnec
1/4-inchfor each rivet. Using a diameter drill, drill out remainder of rivet.
NOTE: Use care not to enlarge sheet metal holes in the door inner panel.
6. Remove three window regulator electric drive retaining screws from inside door to remove window regulator elec
window regulator.
7. Remove two window regulator retaining nuts.8. Remove front door power window regulator from front door.
INSTALLATION
1/4-20 x 1/2 inch 1/4-201. Lubricate regulator mechanism with Teflon(R) Lubricant D2AZ-19590-A or equivalent m
equivalent metric fasteners may be used).
5. Install two upper front door power window regulator retaining nuts.6. Install window regulator electric drive with
> Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair
Rear Door Exterior Handle: Service and Repair

Handle, Outside Door
Removal
NOTE: This procedure applies to front and rear.
1. Remove door trim panel and watershield.
2. Disconnect the door latch actuator rod from the latch.
3. Remove the two rivets retaining the door handle (22404) or rear door outside handle (26604) to the door. Remove
outside handle and rod from the door.
4. Transfer the actuator rod to the new door handle or rear door outside handle
Installation
1. Follow removal procedure in reverse order. Use Heavy Duty Riveter 501-Doll (D80L-23200-A) or equivalent.
> 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 BulletinsInterior 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, THUNDERBIRD1995-1999 CONTOUR, CROWN VICTORIA, MUSTANG1996-1999 E
LINCOLN-MERCURY:1993-1998 MARK VIII1995-1997 COUGAR1995-1999 CONTINENTAL, GRAND MARQU
LIGHT TRUCK:1993-1996 BRONCO1993-1997 F SUPER DUTY, F-250 HD, F-3501993-1999 F-150, F-250 LD199
ISSUEThere has been an increase in the number of door trim panel replacements due to damage. This may be caused b
ACTIONReview the appropriate model/year Service/Workshop Manual, Section 01-05/501-05 prior to removing the d
> Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel -

For a door trim panel with "molded hook" design, Figure 1 displays the correct direction of force applied during the do
WARNING
REMOVE ALL THE SCREWS AND TWO-STAGE PINS BEFORE ATTEMPTING TO REMOVE TRIM PANE
Detailed instructions and illustration can be found in the appropriate model/year Service/Workshop Manual, Section 01
> Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel -

WARRANTY STATUS: INFORMATION ONLYOASIS CODES: 102000, 107000,112000,190000
> Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Page 8538
Rear Door Panel: Service and Repair
Door Panel R&R

Door Panel R&R
Removal
1. Remove one screw from lower rear door panel.
2. Remove window regulator switch housing by gently prying up, starting at front.
> Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Page 8539

3. Disconnect all electrical connectors from window regulator control switch housing.
4. Remove inside door handle cup by gently prying at screwdriver slot.
5. Remove screw directly below release handle.
6. Lift rear door trim panel upward and snap out trim panel.
7. Disconnect any electrical switches if equipped, and remove rear door trim panel.
Installation
1. Follow Removal procedure in reverse order.

> Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair
Rear Door Window Glass: Service and Repair
REMOVAL
1. Remove rear door trim panel and watershield.2. Remove rear door glass run front lower retainer.
CAUTION:
Do not attempt to pry out the rivets as damage to the rear door window glass will result. Prior to removing rivet
3. Lower rear door window glass to gain access to the two rear door window channel bracket retaining rivets and rem
1/4-inchusing a drift punch. Using a diameter drill, drill out the remainder of the rivets.
> Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair > Page 8543

4. Remove rear door window glass.
INSTALLATION
1/4-inch 1/4-20 x 1 inch1. Insert rear door window glass into rear door between rear door glass outside weatherstrip
9-14 N.m (80-124 Lb-In)Tighten bolts (if used) to . Do not exceed maximum torque. Equivalent metric fasteners
4. Install rear door glass run front lower retainer.5. Adjust rear door window glass.6. Install rear door trim panel and
> Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair
Rear Door Window Regulator: Service and Repair

REMOVAL
1. If rear door window glass is in the down position and is inoperable, the following steps must be taken; if rear door
to Step 2.
1/2 incha. Remove rear door trim panel and watershield.b. Mark inner door panel and drill three holes.
Be careful
CAUTION - not to drill through the mechanism behind inner door panel.
- Be careful not to strike or scratch rear door window glass because it can break.
Raise rear
c. Remove reardoor
doorwindow
electricglass to full
window up position
regulator by hand
retaining andthrough
screws secure with a clamp.
holes.d. Remove rear door electric windo
g. Go to Step 4.
CAUTION:
When servicing rear door electric window regulator assembly, regulator cable tension must not be altered. Cable
2. Remove rear door trim panel and watershield.3. Remove rear door window glass.
> Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Page 8547

1/4-inch 1/4-inch4. Disconnect window regulator electric drive harness connector.5. Remove three rivets retaining r
1/4-inch
of rear door electric window regulator to inner panel. Use drift punch to knock out center pins for each rivet. Usin
6. Remove two upper rear door electric window regulator retaining nuts.7. Remove rear door electric window regula
INSTALLATION
1. Lubricate rear door electric window regulator with Teflon(R) Lubricant D2AZ-19590-A or equivalent meeting Fo
ESB-M1C111-A.
2. Install rear bracket.
mounting door electric window regulator into access hole in inner panel.3. Position rear door electric window reg
1/4-20 x 1/2 inch 1/4-204. Install rivets retaining rear door electric window regulator to door inner panel ( bolt and n
equivalent metric fasteners may be used as alternates).
9-14 N.m (80-124 Lb-In)
5. Install two upper rear door electric window regulator retaining nuts. Tighten to .6. Install rear door electric window
> Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Up
Article No.01-19-4
10/01/01
FORD: 1990-1995 ESCORT1990-2000 CROWN VICTORIA1991 TAURUS1992-1995 E SERIES1994 F-150, F-250
PARTS BLOCK

> Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages A
Trunk / Liftgate Lock Cylinder: Technical Service BulletinsLocks - Lock Service Packages Available
Article No.99-24-2
11/29/99

> Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock
Service Packages Available > Page 8559


NOTE

^
^
NOTE

NOTE

NOTE
NOTE

> Body and Frame > Frame > Component Information > Technical Service Bulletins > Recalls: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking
Campaign - Rear Frame Cosmetic Cracking

99B09
Certain 1998-1999 Ford Crown Victoria Police Interceptor, Taxi Cab, & Natural Gas Vehicles (NGV) & Lincoln Town
^ Dealer Letter
^
Administrative
^ Refund Codes
^
Labor Allowances
Attachment II^
^
TechnicalIII^

> Body and Frame > Frame > Component Information > Technical Service Bulletins > Recalls: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Cracking > Page
8572

8573

If a vehicle, registered in New York but not listed in OASIS, is presented for service in that state and has the same pack
PLEASE NOTE
CLAIMSEnter claims using DWE. See ACESII Manual.
OWNER REFUNDSSee ACESII Manual, Section 3 for submission procedures.

OASISOASIS will be activated for this program; however, only vehicles built on or before March 25, 1999 will be acti
For owner-paid repairs of rear frame cracks at the upper control arm access hole made before date of the Owner Letter
8574

LABOR ALLOWANCES
PARTS REQUIREMENTS
^ DOES II
CLAIMS PREPARATIONEnter using DWE.Use code information shown below:
^ Program Code: 99B09
^ Labor Operation: See above
See ACESII manual for detailed instructions.

AFFECTED VEHICLE:1998 AND 1999 CROWN VICTORIA (POLICE, TAXI, NGV), TOWN CAR (LIMO, LIVER
SERVICE PROCEDURE
2. Disconnect battery negative cable.
3. Raise vehicle on hoist and remove rear wheels.
8575

4.
Check to verify torque on both rear suspension upper arm pivot frame bolts is at minimum of 128 Nm (95 lb-ft).
5. Cut off portion of RH flag nut's "flag" that protrudes from frame. See Figure 1.
8576

6. Unclip ABS sensor wire from frame and position aside. Refer to Figure 2.
7. If equipped with air spring, wrap air spring in welding blanket.
8. CAUTION:
If a crack is found, grind only enough metal away to form the V groove. Do not grind completely through fram
9. CAUTION:
Only remove paint and any weld material that interferes with reinforcement plate fit. Do not grind frame parent met
10. NOTE:
Reinforcement plate is properly positioned when the entire access hole is covered and the rear edge is no mor
11. CAUTION:
Burn-through is not permitted. If any burn-through occurs, the hole must be filled. Using standard mig weldin
13. Spray undercoating on plate and welds being careful to avoid any overspray.
14. Reclip ABS sensor wire.
15. Repeat steps 6 through 14 for other side.

8577

16. Install tires. Tighten lug nuts to 129 Nm (95 lb-ft). Lower hoist.
17. Connect battery negative cable.
18. Program radio stations.

8578

> Body and Frame > Frame > Component Information > Technical Service Bulletins > Customer Interest: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Cracking
Frame - Rear Frame Side Member Cracking
Article No. 04-4-1
03/08/04
^
CHASSIS - FRAME CRACKING - SERVICE PROCEDURE
^
SUSPENSION - FRAME CRACKING - SERVICE PROCEDURE
ISSUE
> Page 8584

Some 1998-2002 Crown Victoria vehicles used for heavy-duty type service (Police/Taxi/Limo) may exhibit cracks in t
ACTION
To service, perform the following procedures to repair the cracks and reinforce the frame.
NOTE
READ THESE REPAIR INSTRUCTIONS IN THEIR ENTIRETY BEFORE BEGINNING ANY REPAIR.
NOTE
INSPECT THE VEHICLE FOR COLLISION OR ABUSE-RELATED DAMAGE THAT WOULD HINDER THIS
NOTE
ONE KIT WILL REPAIR ONE SIDE OF THE FRAME. IF THE CONDITION IS OBSERVED ON BOTH SIDES
> Page 8585

NOTE
EACH KIT IS EQUIPPED WITH TW6 (2) REINFORCEMENT PLATES, ONE (1) FOR THE LEFT AND ONE (
Parts Block
040401A Repair Cracks In One 4.2 Hrs.
Frame Rail Then InstallReinforcement Plates AndStructural Foam
040401B Repair Cracks In Both 4.5 Hrs.
Frame Rails Then InstallReinforcement Plates AndStructural Foam

DEALER CODING
CONDITION
BASIC PART NO. CODE
5B118 01
Disclaimer
Service Procedure
NOTE
PERFORM THE FOLLOWING PROCEDURES AS NECESSARY TO REPAIR CRACKS AND REINFORCE O
CAUTION
ALWAYS DISCONNECT THE BATTERY GROUND CABLE PER WORKSHOP MANUAL SECTION 414-01
REAR FRAME AND BODY SPLIT
NOTE
DO NOT PERFORM THIS PROCEDURE IF THERE IS NO CRACK ON THE TOP SURFACE OF THE FRAME
In this procedure the bumper cover will be loosened to prevent damage to the cover when the body of the vehicle is lift
> Page 8586

1.
Position the vehicle on a hoist making sure there is adequate access to the body mount bolts (Figure 4) and the lo
2. Open the hood and disconnect the battery per Workshop Manual Section 414-01.
3. Open the trunk.

4.
Remove/place aside the trunk trim on the sides and remove the four (4) rear bumper cover nuts in the trunk (two
NOTE
IT IS NOT NECESSARY TO REMOVE THE LUGGAGE COMPARTMENT REAR TRIM PANEL.
5. Raise the vehicle to chest height.

> Page 8587

6. Remove the rear wheels.
> Page 8588

7.
Remove the rear bumper cover screws from under the bumper fascia rear lip (two (2) or three (3) screws), (Figure
8. Remove the # 2, 3, 4, 5, and 6 body mount bolts on both sides. Refer to (Figure 4) for locations of body mount bo
NOTE
THE # 4 BODY MOUNT BOLTS ARE NEAR THE SPRING SEAT.
9.
Install a 2X6 block of wood and two (2) jackscrews up tight against the body between the body drain plugs, parti
10.
It present, unclip the ground strap from the # 6 body holes on the frame on the right and left hand sides. The grou
> Page 8589

NOTE
DURING STEP 11, WATCH THE BUMPER COVER TO MAKE SURE IT DOES NOT HANG UP ON THE BU
11.
With the jackscrews and wood supporting the weight of the rear of the body, SLOWLY lower the lift so that the b
12. Raise the hoist and remove the jackscrews.
REPAIR OF FRAME CRACKS BETWEEN THE UPPER AND LOWER TRAILING ARM MOUNTING BRACKET
NOTE
REFER TO (FIGURES 1 AND 2) FOR THE TYPICAL LOCATION OF THE CRACKS. DO NOT PERFORM TH
NOTE
PERFORM THIS REPAIR ON BOTH SIDES OF THE FRAME IF NECESSARY.
> Page 8590

1. If necessary, bend the spot-welded flange at the bottom edge of the inner fender well for improved access~to the
2. On the left side only, remove the brake line clip and reposition the line away from welding area.
3. Use an angle grinder to clean off paint and dress the weld area.
4. Weld crack as necessary.
5. Brush on Motorcraft PM-12-A Low Temperature Anti-Corrosion Coating to all weld repair areas.
6. Replace the brake line.
7. Re-bend weld flange into place.
LOWER TRAILING ARM MOUNTING NUT ACCESS HOLE OPENING REPAIR AND/OR REINFORCEMENT
In this procedure any cracks in the frame area around the lower trailing arm flag nut access hole opening will be repaire
NOTE
THE BLOCKER BAFFLE WILL PREVENT LEAKAGE OF THE STRUCTURAL FOAM, WHICH WILL BE IN
1.
Partially raise the vehicle and locate the access hole for the lower trailing arm. This access hole is located on the
4. Bend two (2) metal Blocker Baffles (one (1) for each side) (4W73-5A145-M) along the crease on the middle of t
> Page 8591

5.
Insert the baffle into the access hole with the narrow end facing upwards. Minimize bending the flanges. The bloc
6.
Once inside the rail section, unbend and position the blocker baffle to get a tight seal to the frame rail section. Pe
a.
On the left hand side bracket, line up the bottom edge of the blocker baffle flange to the rear edge of the acc
b.
On the right hand side bracket, line up the vertical face of the blocker baffle to the rear edge of the access h
7. Grind the area around the access hole in the bottom of the frame at the trailing arm, including any welds that may
> Page 8592

cracks. Grind any welds where needed for proper location of the reinforcement patch (Figure 13). Do not grind aw
> Page 8593

8.
Center the slot of Reinforcement Patch (4W73-5A123-AA right hand side marked "R") or 4W73-5A124-M left h
REINFORCE FRAME WITH STRUCTURAL FOAM
In this procedure the frame rail section will be reinforced with Motorcraft Structural Foam that will add strength to the
> Page 8594

1.
Clean around the tooling hole and all other holes in the area on the frame rail located between the upper and lowe
2. Apply duct tape over the holes.
3.
Pierce a 6 mm (1/4") hole into the duct tape covering the outer tooling hole to allow easy introduction of the nozz
4. Lower the vehicle to chest height.
NOTE
IT IS SUGGESTED THAT GLOVES BE WORN WHEN WORKING THE HEATED TUBES OF MOTORCRAF
> Page 8595

5.
Put the five (5) tubes of 1U2J-19554-DA Motorcraft Structural Foam on a table and heat the tubes front and back
6.
Remove the small black plugs from a tube of structural foam. Install the nozzle (4W73-19H255-M) and replace t
7.
NOTE
REPEAT STEPS 6-7 UNTIL ALL FIVE (5) TUBES OF 1U2J-19554-DA MOTORCRAFT STRUCTURAL FOAM
8. Raise the vehicle all the way up.
9. Remove duct tape.
10. Brush on Motorcraft PM-12-A Low Temperature Anti-Corrosion Coating to the weld areas.
REASSEMBLE FRAME AND BODY
In the following steps the frame will be reassembled to the body, and the bumper fascia will be reinstalled.
NOTE
REQUIRED ONLY IF THE "REAR FRAME AND BODY SPLIT" PROCEDURE WAS PERFORMED.
1. Partially raise the vehicle.
2. Insert the nozzle through the hole cut into the duct tape in the outside tooling hole (Figure 19). Pump the tube of
Reinstall a 2X6 block of wood and two (2) jackscrews up tight against the body between the body drain plugs, pa
3. Lower the hoist until the 2X6 block fits snug against the body.
4.
Remove the wood block between the frame and the body mounts at the # 5 body mount location on each side of t
5. SLOWLY raise the hoist until the frame is off the jackscrews and is flush with the body. Watch the bumper cove
> Page 8596

become damaged.
6. Remove the jackscrews and the 2X6 block from under the vehicle.
7. Clip the ground strap to the #6 body holes on the frame on the right and left hand.
8. Reinstall the # 2, 3, 4, 5, and 6 body mount bolts on both sides.
9. Torque bolts to 48-50 N.m (35.4-36.8 lb-ft).
10. Partially lower the vehicle to waist height.
11. Relocate the bumper fascia and four (4) bumper cover nuts (two (2) on each side).
12. Torque bolts to 7 N.m (61.9 lb-in) (Figure 3 shows left hand side).
13. Reposition trunk trim sides.
15.
Replace the six (6) pin-type retainers (three (3) on each side) in the wheel well leading edge of the bumper (Figur
16. Partially lower the vehicle.
17. Replace the rear wheel and tire assemblies.
18. Lower the hoist.
19. Close the trunk.
20. Reconnect the battery per Workshop Manual: Section 414-01.
21. Close the hood.

> Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member C
Article No. 04-4-1
03/08/04
^
^
ISSUE
> Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame
Side Member Cracking > Page 8602

ACTION
NOTE
NOTE
NOTE

NOTE
Parts Block

DEALER CODING
CONDITION
BASIC PART NO. CODE
5B118 01
Disclaimer
Service Procedure
NOTE
CAUTION
NOTE

1.
3. Open the trunk.

4.
NOTE



7.
NOTE
9.
10.

NOTE
11.
NOTE
NOTE

NOTE
1.

5.
6.
a.
b.


8.

1.
3.
NOTE

5.
6.
7.
NOTE
NOTE
4.

become damaged.
15.
21. Close the hood.

> Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic C

99B09
^ Dealer Letter
^
Administrative
^ Refund Codes
^
Labor Allowances
Attachment II^
^
TechnicalIII^

> Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear
Frame Cosmetic Cracking > Page 8619


PLEASE NOTE


LABOR ALLOWANCES
PARTS REQUIREMENTS
^ DOES II

SERVICE PROCEDURE

4.

8. CAUTION:
9. CAUTION:
10. NOTE:
11. CAUTION:




> Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side Member Crack
Article No. 04-4-1
03/08/04
^
^
ISSUE
> Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other Service Bulletins for Frame: > 04-4-1 > Mar > 04 > Frame - Rear Frame Side
Member Cracking > Page 8631

ACTION
NOTE
NOTE
NOTE

NOTE
Parts Block

DEALER CODING
CONDITION
BASIC PART NO. CODE
5B118 01
Disclaimer
Service Procedure
NOTE
CAUTION
NOTE

1.
3. Open the trunk.

4.
NOTE



7.
NOTE
9.
10.

NOTE
11.
NOTE
NOTE

NOTE
1.

5.
6.
a.
b.


8.

1.
3.
NOTE

5.
6.
7.
NOTE
NOTE
4.

become damaged.
15.
21. Close the hood.

> Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame Cosmetic Crack

99B09
^ Dealer Letter
^
Administrative
^ Refund Codes
^
Labor Allowances
Attachment II^
^
TechnicalIII^

> Body and Frame > Frame > Component Information > Technical Service Bulletins > All Other Service Bulletins for Frame: > 99B09 > Apr > 99 > Campaign - Rear Frame
Cosmetic Cracking > Page 8649


PLEASE NOTE


LABOR ALLOWANCES
PARTS REQUIREMENTS
^ DOES II

SERVICE PROCEDURE

4.

8. CAUTION:
9. CAUTION:
10. NOTE:
11. CAUTION:




> Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Description and Operation
Ash Tray: Description and Operation

An ash receptacle and cigar lighter knob and elements are located in the center of the instrument panel and in the rear a
The cigar lighter knob and element has a low-resistance heating coil which operates much like the coil used in a portab
-
When the cigar lighter knob and element is pushed completely into the cigar lighter socket and retainer, the circu
-
When sufficient heat is generated, the cigar lighter knob and element overcomes the spring pressure of the bi-met
> Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Description and Operation > Page 8660
Ash Tray: Service and Repair
REMOVAL

2. Remove twopanel
instrument screwsashretaining thetoward
receptacle ash receptacle
front of retainer the instrument
vehicle to disengage panel.3.
retaining Lower forward of instrument p
clips.
4. Disconnect ash receptacle wiring at connector.
> Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Description and Operation > Page 8661

5. Remove wiring from ash receptacle bracket. Reach in with a flat-blade screwdriver and lift up on the two spring st
panel ash receptacle from the ash receptacle retainer.
6. Remove cigar lighter knob and element from instrument panel ash receptacle.
INSTALLATION
1. Install cigar lighter knob and element into instrument panel ash receptacle. Install instrument panel ash receptacle
connect wiring harness.
2. Position the ash receptacle clips retainer to the instrument panel and slide rearward to engage retaining clips. Insta
2-3 N.m (18-26 Lb-In)Tighten the screws to .
3. Connect wiring.
> Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming

WARNING:^
air bag module.
one minute (ECS)

WARNING:^
air bag module.

> Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and
Disarming > Page 8667

> Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > P

> Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Service and Repair
Glove Compartment Lock Cylinder: Service and Repair

REMOVAL
1. Open glove compartment and remove lock cover. Remove four screws retaining lock cylinder.2. Remove lock cyl
INSTALLATION
1. To install, reverse Removal procedure.
> Body and Frame > Jack > Component Information > Technical Service Bulletins > Recalls for Jack: > NHTSA00V200000 > Jul > 00 > Recall 00V200000: Jack Use, Stowage, & Warning
Jack: RecallsRecall 00V200000: Jack Use, Stowage, & Warning Revisions
Vehicle Description: Passenger vehicles. These vehicles have jacking instructions which, if followed, could cause the
> Body and Frame > Jack > Component Information > Technical Service Bulletins > Recalls for Jack: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure
SAFETY RECALL00S13
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
Attachment

> Body and Frame > Jack > Component Information > Technical Service Bulletins > Recalls for Jack: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure > Page 8685

PLEASE NOTE
PROMPTLY CORRECT

LABOR ALLOWANCES
PARTS REQUIREMENTS


NOTE:

NOTE:
1.

1.


> Body and Frame > Jack > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Jack: > NHTSA00V200000 > Jul > 00 > Recall 00V200000: Jack Us
Jack: All Technical Service BulletinsRecall 00V200000: Jack Use, Stowage, & Warning Revisions
Vehicle Description: Passenger vehicles. These vehicles have jacking instructions which, if followed, could cause the
> Body and Frame > Jack > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Jack: > 00S13 > Jul > 00 > Recall - Vehicle Jacking Procedure
SAFETY RECALL00S13
^ Dealer Letter
^
Administrative
^
Labor Allowances
Attachment II^
^
Attachment

> Body and Frame > Jack > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Jack: > 00S13 > Jul > 00 > Recall - Vehicle Jacking

PLEASE NOTE
PROMPTLY CORRECT

LABOR ALLOWANCES
PARTS REQUIREMENTS


NOTE:

NOTE:
1.

1.


> Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available
Door Lock Cylinder: Technical Service BulletinsLocks - Lock Service Packages Available
Article No.99-24-2
11/29/99

> Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page
8714

8715

NOTE
8716

^
^
NOTE
8717

NOTE
8718

NOTE
NOTE

> Body and Frame > Locks > Door Locks > Door Module > Component Information > Locations

Full Body View
> Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Diagrams
Remote Keyless Entry Switch Assembly

> Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Diagrams > Page 8726
Keyless Entry Key-Pad: Description and Operation

CAUTION: Do not use a key, pencil or any other hard object to press the keyless entry keypad buttons. These objects
- To unlock the driver door enter the permanent factory code or enter the owner's alternate code (if programmed).
- five secondsTo unlock the passenger door(s), press the 3/4 button within of unlocking the driver door or luggage
- five secondsTo unlock the luggage compartment door, press the 5/6 button within of unlocking driver or passeng
-
To turn on the courtesy lamps and light all illuminated components, lift either front door handle (only if not equip
-
To lock all doors, press the 7/8 and 9/0 buttons at the same time with all doors closed. (It is not necessary to enter
To program an alternate keyless entry keypad code:
five seconds
1. Enter the five digit permanent entry code into keyless entry keypad.2. Within of pressing last button of permanent
> Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Diagrams > Page 8727
Keyless Entry Key-Pad: Service and Repair

REMOVAL
1. Disconnect battery ground cable.2. Remove front door trim panel.3. Disconnect door lock switch actuator wiring h
INSTALLATION
> Body and Frame > Locks > Keyless Entry > Driver's Door Module <--> [Keyless Entry Module] > Component Information > Service and Repair

REMOVAL
INSTALLATION
> Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair
Keyless Entry Transmitter Battery: Service and Repair
REMOVAL
1. Twist a thin coin between the two halves of the keyless entry remote transmitter.
CAUTION: Do not take the front half of the transmitter apart.
NOTE:
The keyless entry remote transmitter is powered by one coin-type, three-volt lithium batteries. Install new batter
2. Carefully swing the contacts off the battery and remove the old battery.
INSTALLATION
1. Carefully swing the contacts back onto the top of the battery.2. Snap the two halves of the transmitter back togethe
> Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Specifications
Power Door Lock Actuator: Specifications
Front Door Lock Actuator Screws .......................................................................................................................................

> Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Specifications > Page 8739
Power Door Lock Actuator: Testing and Inspection

12 volts1. Apply directly to the power door lock actuator terminals (reverse polarity for opposite direction). The pow
one secondshould finish its travel in less than .
6 amps2. Using Rotunda 73 Digital Multimeter 105-R0051 or equivalent, the power door lock actuator current draw
Reverse the polarity to the connector and retest.
Power Door Lock Actuator: Service and Repair
Front Door Lock Actuator


Rear Door Lock Actuator
REMOVAL
NOTE: This procedure covers front and rear.

1. Remove door trim panel.2. Remove the watershield.3. Remove rivet retaining power door lock actuator or rear doo
INSTALLATION
> Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Locations

> Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8747


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:





> Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Diagrams > Page 8759

REMOVAL
INSTALLATION
> Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Master
> Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Master > Page 8764
> Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 8765

5 ohms
5 ohms
> Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 8766

REMOVAL
INSTALLATION
> Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available
Trunk / Liftgate Lock Cylinder: Technical Service BulletinsLocks - Lock Service Packages Available
Article No.99-24-2
11/29/99

> Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page
8771

8772

NOTE
8773

^
^
NOTE
8774

NOTE
8775

NOTE
NOTE

> Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions
Heated Element: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 8781


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
Rear Window Defrost

> Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Locations

> Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8794


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:





> Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair
Power Mirror Motor: Service and Repair
REMOVAL
1. Disconnect battery ground cable.2. Remove outside rear view mirror glass.3. Remove outside rear view mirror.4. R
INSTALLATION
> Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams
Power Mirror Switch

> Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Page 8812
REMOVAL
INSTALLATION
> Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 99-12-10 > Jun > 99 > Paint - Rough Texture
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 E
FORD:1996-1997 ASPIRE, PROBE, THUNDERBIRD1996-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUS
LIGHT TRUCK: 1996 BRONCO1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-3501996-1999 ECONOLIN
MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES1996-1998 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
ISSUEFord Motor Company has released a private labeled material to be used for iron particle/acid rain service repairs
> Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 99-12-10 > Jun > 99 > Paint - Rough
Texture > Page 8822

ACTIONTo remove these particles/contaminates, use ONLY the following products and procedure. No polishing, com
Texture > Page 8823

Parts Block
SUPERSEDES: 97-21-3
WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage
991210A Decontaminate And 0.6 Hr.
Surface Correction (Aspire,F-450/550, And Cargo)
991210B Decontaminate And 0.7 Hr.
Surface Correction (EscortZX2, Ranger Regular Cab,Probe, Bronco, AndAerostar)

991210C Decontaminate And 0.8 Hr.
Surface Correct(Escort/Tracer,Escort/Tracer Wagon,Contour/Mystique, MustangConvertible/Conve

991210D Decontaminate And 0.8 Hr.
Surface Correction(F-Series And 1996-97Thunderbird/Cougar)

991210E Decontaminate And 0.8 Hr.
Surface Correction (RangerSuperCab/Splash,F-150/250 6Ft Bed -Regular Cab/Flare Side -Regular C

991210F Decontaminate And 0.9 Hr.
Surface Correction(Mustang Coupe/CoupeGT, Continental, Mark VIII,Ranger Splash SuperCab,Exp

991210G Decontaminate And 0.9 Hr.
Surface Correction(F-150/250 6Ft Bed -SuperCab/8Ft Bed -
Texture > Page 8824

Regular Cab/Flare Side -SuperCab, And F-250/350SD 6Ff Bed -SuperCab/8Ft Bed -Regular Cab)
991210H Decontaminate And 1.0 Hr.
Surface Correction (CrownVictoria/Grand Marquis,Town Car, Windstar,Explorer 4-Door, AndMou

9912101 Decontaminate And 1.0 Hr.
Surface Correction(F-150/250 8Ft Bed -SuperCab, F-250/350 SD6Ft Bed - Crew Cab/8FtBed - Supe
991210J Decontaminate And 1.2 Hrs.
Surface Correction(Econoline Wagon/WagonSuper-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
NOTE
THE PRODUCTS USED TO REMOVE SURFACE CONTAMINATION FROM PAINT ARE DESIGNED FOR V
Identification
Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, etc. These particles me
Concern Description
Ferrous Metal
Light Colored Vehicles: Small orange stains the size of "mechanical pencil lead." The surface is rough to the touch.
Texture > Page 8825

Dark Colored Vehicles: Small white or silver appearing dots with a rainbow ring around the dot. The surface is rough t
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. Pe
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
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.
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 veh
NOTE
DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE USED F
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 O
POLISHING, BUFFING, COLOR SANDING, OR IN EXTREME CASES, REFINISHING.
2. Do Not Intermix Buffing Products. Use only one manufacturer's products.
3. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser squirt bottle. Squir
Always follow the manufacturer's product usage sequence. Use the appropriate recommended pad at recommend
NOTE
WHEN ATTEMPTING TO AFFECT A REPAIR BY BUFFING, POLISHING, OR COLOR SANDING, DO NOT
4. Use a dual action sander with a Velcro backing plate and a foam pad to fine polish and remove any swirls created
Texture > Page 8826

5.
Use an alcohol and water mixture (1 to 1 ratio) to clean the buffed areas and to verify removal of scratches and sw
> 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 - Roug
Article No.99-12-10
06/14/99
^
> 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 8832


Parts Block
SUPERSEDES: 97-21-3







DEALER CODING
CONDITION
BASIC PART NO. CODE
ENTRE C8
OASIS CODES: 106000,190000
Service Procedure
NOTE
NOTE
Identification
Concern Description
Ferrous Metal

Industrial Fallout
Acid Rain/Etching

3.
NOTE
6.
NOTE
NOTE
NOTE

5.
> 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 - Mater
Repairs
Paint: All Technical Service BulletinsPaint - Materials For After Warranty/Warranty Repairs
Article No.98-18-2
09/14/98
PAINT - EXTERIOR - WORLDWIDE RECOMMENDED PAINT MATERIALS FOR WARRANTY AND AFTER W
FORD:1997 ASPIRE, PROBE, THUNDERBIRD1997-98 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG,
LINCOLN-MERCURY:1997 COUGAR1997-98 CONTINENTAL, GRAND MARQUIS, MARK VIII, MYSTIQUE,
LIGHT TRUCK:1997 AEROSTAR1997-98 ECONOLINE, EXPEDITION, EXPLORER, F SUPER DUTY, F-150-35
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
ACTION
Ford Customer Service Division (FCSD) has released a paint material specification (WSS-M2P100-D) to the major wo
SYSTEMS TESTED
Ford Motor Company has completed testing of refinish paint materials that are compliant to U.S. "National Rule," "Can
NOTE
TESTING OF CALIFORNIA VOC COMPLIANT SYSTEMS WILL BEGIN 9/98 DUE TO A RECENT MORAT
SELECTION AND PREPARATION

Each paint manufacturer was asked to submit worldwide "in-use" paint systems for testing. The paint materials used fo
SUBSTRATES AND TESTS
The paint materials approved from these specifications were tested over the following substrates: cold rolled steel, E-co
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
> 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 8841

Systems will only be tested once a year. Cost of testing will be the responsibility of the paint suppliers.
APPROVED SUPPLIERS AND MATERIALS







The Charts following this article (Figures 1-7) indicate paint suppliers and materials. Dealers should begin to use the re
CONCLUSIONS
Testing of refinish materials will raise standards for these materials. These improved standards will result in improved

SUPERSEDES: 98-9-3
OASIS CODES: 106000, 190000

> 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 C
Tip
Paint: All Technical Service BulletinsPaint - 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 C
LIGHT TRUCK: 1997 AEROSTAR
1998 ECONOLINE, EXPEDITION, EXPLORER, F SUPER DUTY, F-150, F-250 LD, MOUNTAINEER, NAVIGAT
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
ACTION: Remove the affected material, apply repair material, and paint. Refer to the following Service Procedure for
WARNING:
WEAR RESPIRATORY PROTECTION. WEAR PROTECTIVE CLOTHING WHEN EVER POTENTIALLY HA
Areas that have been treated with Anti-chip Stone Abrasion materials show more textured appearance than the other pa
NOTE:
THIS PROCEDURE HIGHLIGHTS BASF STONE ABRASION MATERIAL; HOWEVER, OTHER MATERIAL
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 R
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 EQ

> 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 8853

BAKE TIME 30 MINUTES AT 60C (140F) OR INFRA-RED LIGHT 7-20 MINUTES. AIR DRY 2 HOURS. REM
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
OASIS CODES: 106000

> 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
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, THUNDERBIRD1997-98 CONTOUR1998 CROWN VICTORIA, ESCORT, MUSTA
LINCOLN-MERCURY: 1997 COUGAR1997-98 MYSTIQUE1998 CONTINENTAL, GRAND MARQUIS, MARK V
LIGHT TRUCK: 1997 AEROSTAR1997-98 EXPEDITION, EXPLORER, F-150, F-250 LD, F-250 LD, MOUNTAIN
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 resto
ACTION: The following procedure is applicable to repair surface conditions such as dirt particles, "orange peel," runs,
Parts Block
Preparation
The affected surface must be clean and dry to be repaired. Mask off adjacent panels, mouldings, stripe, and character li
CAUTION:
EYE PROTECTION SHOULD BE WORN. JEWELRY, WATCHES, AND BELT BUCKLES MUST BE REMOV
NOTE:
CHECK PAINT FILM THICKNESS BEFORE AND AFTER PERFORMANCE OF REPAIRS. MAXIMUM PAIN
> 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 8858

A MIL.
NOTE:
PERFORM A TRIAL REPAIR ON A SMALL AREA. FIRST, TRY A POLISH; IF THIS IS NOT SUCCESSFUL
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
3.
Remove light scratches and small dirt particles with a power buffer and Ford Medium Duty Body Shop Pain Clea
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 buf
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
^
When "buffing out" oxidation or other paint defects with a cleaning material, use a liberal amount of material
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 AC
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
NOTE:
ALWAYS KEEP THE PAD MOVING AND LIMIT YOUR STROKES OVER THE BLEMISH TO PREVENT EX
NOTE:
HEAT BUILDUP: WHEN BUFFING CREATES EXCESSIVE HEAT, HAZING MAY APPEAR ACROSS THE
NOTE:
STATIC: STATIC ELECTRICITY MAY BE PRESENT ON A PAINTED FIBERGLASS/PLASTIC SURFACE B

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
NOTE:
> Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-3-3 > Feb > 98 >

IF IT IS NECESSARY TO SHAVE RUNS AND SAGS WITH A RAZOR BLADE, FIRST DULL THE CORNER
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,
^ 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. Th
1. Mist or apply water on the area to be sanded. Continue to flush water on the surface during sanding for maximum
2. Use sanding blocks or paper. Keep abrasion to the immediate area of the defect. Keep blocks in water when not i
3.
If the cutting is too slow, switch to a lower grade block or paper and resume sanding. When 90% of the defect is
4. Sanding blocks can be shaped to work on any angle. When the block is wet, rub it against a dry sanding block for
5.
When using sanding papers, wrap the paper tightly around a backing pad. This pad evenly distributes pressure ov
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, h
NOTE:
IF MULTIPLE GRIT PAPERS ARE USED, IT IS A GOOD IDEA TO CHANGE THE DIRECTION OF SANDIN
8.
Buff out sanding marks by applying Ford Medium Duty Body Shop Paint Cleaner with a "Foam" Cutting Pad (W
General Techniques and Hints
^ "Foam" buffing pads yield maximum gloss and depth of color on all types of paint finishes without creating buffer s
^ Always apply product directly to pad, not to oxidized paint surface. Dry paint absorbs material into pores upon cont
^
Avoid short rapid strokes. Move the buffer slowly across the surface using long straight motions and overlap by 50%
^
Avoid buffing directly on raised character lines. The reduced paint film on these surfaces increases the risk of paint
^
If a paint blemish remains after buffing, reapply a small amount of material over the blemish~ Confine your buffing
> 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
Paint: All Technical Service BulletinsPaint - Materials For After Warranty/Warranty Repairs
Article No.98-18-2
09/14/98
PAINT - EXTERIOR - WORLDWIDE RECOMMENDED PAINT MATERIALS FOR WARRANTY AND AFTER W
FORD:1997 ASPIRE, PROBE, THUNDERBIRD1997-98 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG,
LINCOLN-MERCURY:1997 COUGAR1997-98 CONTINENTAL, GRAND MARQUIS, MARK VIII, MYSTIQUE,
LIGHT TRUCK:1997 AEROSTAR1997-98 ECONOLINE, EXPEDITION, EXPLORER, F SUPER DUTY, F-150-35
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
ACTION
Ford Customer Service Division (FCSD) has released a paint material specification (WSS-M2P100-D) to the major wo
SYSTEMS TESTED
Ford Motor Company has completed testing of refinish paint materials that are compliant to U.S. "National Rule," "Can
NOTE
TESTING OF CALIFORNIA VOC COMPLIANT SYSTEMS WILL BEGIN 9/98 DUE TO A RECENT MORAT
SELECTION AND PREPARATION

Each paint manufacturer was asked to submit worldwide "in-use" paint systems for testing. The paint materials used fo
SUBSTRATES AND TESTS
The paint materials approved from these specifications were tested over the following substrates: cold rolled steel, E-co
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
> 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 8865

Systems will only be tested once a year. Cost of testing will be the responsibility of the paint suppliers.
APPROVED SUPPLIERS AND MATERIALS







The Charts following this article (Figures 1-7) indicate paint suppliers and materials. Dealers should begin to use the re
CONCLUSIONS
Testing of refinish materials will raise standards for these materials. These improved standards will result in improved

SUPERSEDES: 98-9-3
OASIS CODES: 106000, 190000

> 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
Paint: All Technical Service BulletinsPaint - 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 C
LIGHT TRUCK: 1997 AEROSTAR
1998 ECONOLINE, EXPEDITION, EXPLORER, F SUPER DUTY, F-150, F-250 LD, MOUNTAINEER, NAVIGAT
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
ACTION: Remove the affected material, apply repair material, and paint. Refer to the following Service Procedure for
WARNING:
WEAR RESPIRATORY PROTECTION. WEAR PROTECTIVE CLOTHING WHEN EVER POTENTIALLY HA
Areas that have been treated with Anti-chip Stone Abrasion materials show more textured appearance than the other pa
NOTE:
THIS PROCEDURE HIGHLIGHTS BASF STONE ABRASION MATERIAL; HOWEVER, OTHER MATERIAL
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 R
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 EQ

> 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 8877

BAKE TIME 30 MINUTES AT 60C (140F) OR INFRA-RED LIGHT 7-20 MINUTES. AIR DRY 2 HOURS. REM
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
OASIS CODES: 106000

> 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 De
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, THUNDERBIRD1997-98 CONTOUR1998 CROWN VICTORIA, ESCORT, MUSTA
LINCOLN-MERCURY: 1997 COUGAR1997-98 MYSTIQUE1998 CONTINENTAL, GRAND MARQUIS, MARK V
LIGHT TRUCK: 1997 AEROSTAR1997-98 EXPEDITION, EXPLORER, F-150, F-250 LD, F-250 LD, MOUNTAIN
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 resto
ACTION: The following procedure is applicable to repair surface conditions such as dirt particles, "orange peel," runs,
Parts Block
Preparation
The affected surface must be clean and dry to be repaired. Mask off adjacent panels, mouldings, stripe, and character li
CAUTION:
EYE PROTECTION SHOULD BE WORN. JEWELRY, WATCHES, AND BELT BUCKLES MUST BE REMOV
NOTE:
CHECK PAINT FILM THICKNESS BEFORE AND AFTER PERFORMANCE OF REPAIRS. MAXIMUM PAIN
> Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-3-3 > Feb > 98 >

A MIL.
NOTE:
PERFORM A TRIAL REPAIR ON A SMALL AREA. FIRST, TRY A POLISH; IF THIS IS NOT SUCCESSFUL
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
3.
Remove light scratches and small dirt particles with a power buffer and Ford Medium Duty Body Shop Pain Clea
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 buf
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
^
When "buffing out" oxidation or other paint defects with a cleaning material, use a liberal amount of material
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 AC
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
NOTE:
ALWAYS KEEP THE PAD MOVING AND LIMIT YOUR STROKES OVER THE BLEMISH TO PREVENT EX
NOTE:
HEAT BUILDUP: WHEN BUFFING CREATES EXCESSIVE HEAT, HAZING MAY APPEAR ACROSS THE
NOTE:
STATIC: STATIC ELECTRICITY MAY BE PRESENT ON A PAINTED FIBERGLASS/PLASTIC SURFACE B

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
NOTE:
> Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-3-3 > Feb > 98 >

IF IT IS NECESSARY TO SHAVE RUNS AND SAGS WITH A RAZOR BLADE, FIRST DULL THE CORNER
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,
^ 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. Th
1. Mist or apply water on the area to be sanded. Continue to flush water on the surface during sanding for maximum
2. Use sanding blocks or paper. Keep abrasion to the immediate area of the defect. Keep blocks in water when not i
3.
If the cutting is too slow, switch to a lower grade block or paper and resume sanding. When 90% of the defect is
4. Sanding blocks can be shaped to work on any angle. When the block is wet, rub it against a dry sanding block for
5.
When using sanding papers, wrap the paper tightly around a backing pad. This pad evenly distributes pressure ov
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, h
NOTE:
IF MULTIPLE GRIT PAPERS ARE USED, IT IS A GOOD IDEA TO CHANGE THE DIRECTION OF SANDIN
8.
Buff out sanding marks by applying Ford Medium Duty Body Shop Paint Cleaner with a "Foam" Cutting Pad (W
General Techniques and Hints
^ "Foam" buffing pads yield maximum gloss and depth of color on all types of paint finishes without creating buffer s
^ Always apply product directly to pad, not to oxidized paint surface. Dry paint absorbs material into pores upon cont
^
Avoid short rapid strokes. Move the buffer slowly across the surface using long straight motions and overlap by 50%
^
Avoid buffing directly on raised character lines. The reduced paint film on these surfaces increases the risk of paint
^
If a paint blemish remains after buffing, reapply a small amount of material over the blemish~ Confine your buffing
> Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 8884
Paint: By Symptom
Article No.99-12-10
06/14/99
^



Parts Block
SUPERSEDES: 97-21-3







DEALER CODING
CONDITION
BASIC PART NO. CODE
ENTRE C8
OASIS CODES: 106000,190000
Service Procedure
NOTE
NOTE
Identification
Concern Description
Ferrous Metal

Industrial Fallout
Acid Rain/Etching

3.
NOTE
6.
NOTE
NOTE
NOTE

5.
Use an alcohol
99-12-10
and water
Technical
mixture
Service
(1 toBulletin
1 ratio) to
# clean the buffed areas and to verify removal of scratches and sw
Article No.99-12-10
06/14/99
^



Parts Block
SUPERSEDES: 97-21-3







DEALER CODING
CONDITION
BASIC PART NO. CODE
ENTRE C8
OASIS CODES: 106000,190000
Service Procedure
NOTE
NOTE
Identification
Concern Description
Ferrous Metal

Industrial Fallout
Acid Rain/Etching

3.
NOTE
6.
NOTE
NOTE
NOTE

5.
> Body and Frame > Relays and Modules - Body and Frame > Door Module > Component Information > Locations

Full Body View
> Body and Frame > Relays and Modules - Body and Frame > Driver's Door Module <--> [Keyless Entry Module] > Component Information > Service and Repair

REMOVAL
INSTALLATION
> Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Locations

> Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8914


> Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8916



> Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Diagrams > Page 8919

REMOVAL
INSTALLATION
> Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Locations

> Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 8925

Page 8926

System Diagrams
Page 8927

Grounds Diagrams
Page 8928

ELECTRICAL SYMBOLS
Electrical Symbols
Page 8929

Electrical Symbols
VACUUM SYMBOLS
Page 8930

Vacuum Symbols

BK
BL
BR
Page 8931

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8932

Page 8933

> Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8934

Page 8935

Page 8936

> Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Driver's Door Module

> Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Driver's Door Module > Page 8941


> Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 8944

Page 8945

System Diagrams
Page 8946

Grounds Diagrams
Page 8947

ELECTRICAL SYMBOLS
Electrical Symbols
Page 8948

Electrical Symbols
VACUUM SYMBOLS
Page 8949

Vacuum Symbols

BK
BL
BR
Page 8950

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8951

Page 8952

> Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8953

Page 8954

Page 8955

> Body and Frame > Seats > Head Rest > Component Information > Description and Operation
Head Rest: Description and Operation

Each front seat is equipped with dual-post design front seat back head restraint.
The front seat back head restraint functions as follows:
- The front seat back head restraint travels on dual posts which have notches to engage a spring-loaded catch in the
- The front seat head rest guide rod retainer retains the front seat head rest guide rod sleeve.
- 25 mm (1 inch)The front seat back head restraint is adjustable from its normal position to a raised position of app
- Pull up on the front seat back head restraint to raise it. Pushing down will return it to its normal position.
- 60 degreesThe restraint may be tilted forward from its normal position up to .
> Body and Frame > Seats > Head Rest > Component Information > Description and Operation > Page 8960
Head Rest: Service and Repair
REMOVAL
1. Unscrew front seat head rest guide rod retainers.2. Pull up on front seat back head restraint. Compress foam in are
INSTALLATION
1. Slide front seat head rest guide rod retainers onto front seat back head restraint posts.2. Compress foam in front se
positioning spring.
4. Tighten front seat head rest guide rod retainers onto front seat head rest guide rod sleeves.5. Adjust front seat back
NOTE:
Front seat back head restraint must operate smoothly throughout its range of travel, must remain in any fixed po
> Body and Frame > Seats > Power Seat Control Module > Component Information > Locations > Driver's Door Module

> Body and Frame > Seats > Power Seat Control Module > Component Information > Locations > Driver's Door Module > Page 8965


> Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8968


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:





> Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver's Seat Motor Assembly
Power Seat Motor: DiagramsDriver's Seat Motor Assembly
Driver's Power Seat Motor (With Power Recliner/Lumbar) (C325)

Driver's Power Seat Motor (Without Power Recliner/Lumbar) (C325) Passenger's Power Seat Motor (With Po
> Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver's Seat Motor Assembly > Page 8984
Driver's Power Seat Motor (Without Power Recliner/Lumbar) (C325) Passenger's Power Seat Motor (With Po
> Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Height Position Sensor
Front

Rear
> Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Height Position Sensor > Page 8989





> Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > With Power Reclining Seats

> Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > With Power Reclining Seats > Page 8996

> Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Power-Six-Way With Power Recliner
REMOVAL
INSTALLATION
> Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Power-Six-Way With Power Recliner > Page 8999
REMOVAL
INSTALLATION
> Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Seat Leather - Cleaning Procedure Tips
Seat Cover: Technical Service BulletinsSeat Leather - Cleaning Procedure Tips
Article No.98-17-1
09/01/98
SEAT - LEATHER CLEANING PROCEDURE - SERVICE TIP
FORD:1984-94 TEMPO1984-97 THUNDERBIRD1984-98 CROWN VICTORIA, ESCORT, MUSTANG1986-98 TA
LINCOLN-MERCURY: 1984-94 TOPAZ1984-97 COUGAR1984-98 GRAND MARQUIS, TRACER1984-99 TOWN
LIGHT TRUCK:1983-98 RANGER1984-96 BRONCO1984-97 F-250 HD1984-98 ECONOLINE, F-150, F-250 LD19
This TSB article is being republished in its entirety to include the latest level parts and to include a revised Service Pro
ISSUE
The following TSB contains information regarding the cleaning of interior leather seats and trim. Improper cleaning pr
ACTION
Ford Motor Company has developed a new kit (Deluxe Leather Care Kit - F8AZ-19G253-AA) to clean soiled seats wit
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 s
Use this material on leather and vinyl seats that:
^ show excessive soiling
^ have been stained with coffee, lipstick, etc.

> Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Seat Leather - Cleaning Procedure Tips > Page 9004

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.
F8AZ-19G253-AA Deluxe Leather Care Kit
SUPERSEDES: 97-14-2
OASIS CODES: 101000, 107000, 190000

> Body and Frame > Seats > Seat Latch > Component Information > Specifications > Mechanical Specifications
Seat Latch: Mechanical Specifications
Front Seat Back Latch-to-Front Seat Back Frame Retaining Screws ..................................................................................
> Body and Frame > Seats > Seat Latch > Component Information > Specifications > Mechanical Specifications > Page 9009
Seat Latch: Fluid Type Specifications

Multi Purpose Grease ...........................................................................................................................................................
> Body and Frame > Seats > Seat Latch > Component Information > Specifications > Page 9010
Seat Latch: Adjustments
The manual front seat back latch and power seat back adjuster assembly are modular components and do not require ad
The only authorized service permitted on either the manual front seat back latch or power seat back adjuster assembly i
- Tightening of all retaining screws.
- Replacement (in entirety) of a damaged or non-functional manual front seat back latch or power seat back adjuste
- Removal of any foreign material, such as tie straps, pieces of foam and trim.
If a manual front seat back latch or power seat back adjuster assembly is non-functional or damaged, the entire manual
> Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Manual Recliner - Split Bench
Seat Latch: Service and RepairManual Recliner - Split Bench
REMOVAL
1. Remove spring clip retaining front seat back adjusting handle and remove front seat back adjusting handle from fr
NOTE:
The manual front seat back latch is a modular design and components cannot be serviced or replaced individual
2. Detach J-retainer and arrow retainers at outboard rear corner and J-retainer from cushion frame side. Pull back trim
INSTALLATION
NOTE: Check front seat back latch for proper operation prior to positioning front seat back cover and front seat
23-32 N.m (17-23 Lb-Ft)2. Tighten front seat back latch retaining screws to .
> Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Manual Recliner - Split Bench > Page 9013
Seat Latch: Service and RepairPower Recliner

REMOVAL
1. Disengage J-retainer and arrow retainers at outboard RH rear corner and J-retainer from cushion frame side. Pull b
NOTE:
The power seat back adjuster is a modular design and components cannot be serviced or replaced individually. T
2. Remove push pin retainers and remove trim cover from power seat back adjuster.3. Disconnect front seat back pad
back assembly.
5. Disengage J-retainers at bottom of front seat back assembly and pull up front seat back cover.6. Remove two screw
INSTALLATION
23-32 N.m (17-23 Lb-Ft)1. Follow removal procedure in reverse order.2. Tighten power seat back adjuster retaining
> Body and Frame > Seats > Seat Track > Component Information > Specifications > Mechanical Specifications
Seat Track: Mechanical Specifications
Power Seat Track-to-Floor Nut-Outboard ...........................................................................................................................

> Body and Frame > Seats > Seat Track > Component Information > Specifications > Mechanical Specifications > Page 9018
Seat Track: Fluid Type Specifications

Multi Purpose Grease ...........................................................................................................................................................
> Body and Frame > Seats > Seat Track > Component Information > Description and Operation > Manual Seat Track
Seat Track: Description and OperationManual Seat Track

The manual seat system has these features:
- The front seat cushion extension handle located at front of seat.
- Pulling the front seat cushion extension handle allows the seat to move forward or rearward.
-
Manual front seat tracks are retained to the front floor pan by studs with nut and washer assemblies and washer h
- The front and rear seat trim is attached to the seat frames with retainers and hog rings, and is available in vinyl, c
> Body and Frame > Seats > Seat Track > Component Information > Description and Operation > Manual Seat Track > Page 9021
Seat Track: Description and OperationPower Seat Track
The six-way power seat has the following features:

- horizontal, vertical and tilt adjustments
- a seat regulator motor and gear housing
-- seat regulator
vertical control switch
gear drives
- horizontal rack-and-pinion drives
- The front and rear seat trim is attached to the seat frames with retainers and hog rings, and is available in vinyl, c
The system operates as follows:

- The mechanical portion of the front seat track in the horizontal drive consists of a rack-and-pinion drive on each
- The pinion housing and seat regulator motor is attached to the movable section of the track.
-
When the horizontal position of the seat regulator control switch is actuated, the center armature is energized and
- The seat is then moved forward or rearward by the pinion gears traveling in a rack in each lower track section.
- In the vertical drive, worm gear reducers and sector gear mechanisms are used.
- The drive units are located in the front and rear of the transmission case.
> Body and Frame > Seats > Seat Track > Component Information > Description and Operation > Manual Seat Track > Page 9022

-
When the seat regulator control switch is actuated to move entire seat vertically, the front and rear armatures are
- The seat is then moved up or down by the sector gears.
-
When the front tilt portion of the seat regulator control switch is actuated, the front armature drives the front verti
-
When the rear tilt portion of the seat regulator control switch is actuated, the rear armature drives the rear vertical
The main components of the system are serviced as follows:

- Seat regulator motors and transmission are serviced as a unit.
- Seat regulator control switch and housing assembly are serviced separately.
Circuit Protection
Circuit
20 Aprotection
Circuit protection
is provided
to the
as follows:-
base power seats is provided by the Door Locks/Seat Motors circuit breaker located
- The power seat motor circuit is protected by circuit breakers mounted in each seat regulator motor armature.
> Body and Frame > Seats > Seat Track > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Seat Track: Initial Inspection and Diagnostic Overview
1. Verify the customer's concern by operating the power seat(s) to duplicate the condition.2. Inspect to determine if o
Seat tracks
Mechanical - obstructed.
- Seat at limit(s) of travel.
- Damaged lumbar support hose.
- Damaged lumbar support switch and valve.
20 AOpen
Electrical - Door Lock/Seat Motor circuit breaker in power distribution box.
- Loose, corroded or damaged connectors.
- Damaged switches.
- Damaged motors.
3. If inspection reveals an obvious concern that is readily serviceable, correct the concern before continuing with Ins
> Body and Frame > Seats > Seat Track > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9025
Seat Track: Pinpoint Tests
Test Notes
Use Rotunda 73 Digital Multimeter 105-00051 or equivalent to perform pinpoint tests.
A1 - A2

A3 - A5

B1 - B3

C1 - C2
D1 - D2

E1 - E8

E9 - E10
> Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Manual Seat Track
Seat Track: Service and RepairManual Seat Track

REMOVAL
1. Remove seat and track assembly.2. Place seat and track assembly upside down on a clean bench.3. Disconnect fro
NOTE: To ease front seat track assist spring removal and installation, adjust seat to full forward position.
4. Remove the seat track-to-front seat cushion frame and spring retaining screws and remove front seat track assemb
INSTALLATION
17-23 N.m (13-16 Lb-Ft)1. Follow removal procedure in reverse order.2. Tighten the seat track-to front seat cushion
> Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Manual Seat Track > Page 9034
Seat Track: Service and RepairPower Six-Way
RH Shown LH Similar
REMOVAL
1. Remove seat and track assembly.2. Place the seat and track assembly upside down on a clean bench.3. Disconnect
end.
7. Remove front seat center passenger belt from mounting slot and remove front seat track assembly from front seat c
INSTALLATION
17-23 N.m (13-16 Lb-Ft)

34-46 N.m (25-34 Lb-Ft)
1. Follow removal procedure in reverse order.2. Tighten bolts retaining front seat track to front seat cushion frame an
> Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Vacuum/Pressure Pump Switch, Seats > Component Information > Service and Repair

REMOVAL
INSTALLATION
pad adjusting pump.

> Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Sw
Article No.01-19-4
10/01/01
PARTS BLOCK

> Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Master
> Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Master > Page 9049
> Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 9050

5 ohms
5 ohms
> Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 9051

REMOVAL
INSTALLATION
> Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams
Power Mirror Switch

> Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 9055
REMOVAL
INSTALLATION
> Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Height Position Sensor
Front

Rear
> Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Height Position Sensor > Page
9060


> Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Height Position Sensor > Page 9061


> Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Height Position Sensor > Page 9062

> Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > With Power Reclining Seats

> Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > With Power Reclining Seats > Page 9067

> Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Power-Six-Way With Power Recliner
REMOVAL
INSTALLATION
> Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Power-Six-Way With Power Recliner > Page 9070
REMOVAL
INSTALLATION
> Body and Frame > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch, Seats > Component Information > Service and Repair

REMOVAL
INSTALLATION
pad adjusting pump.

> Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 99-4-5 > Mar > 99 > Right Hand Windshield - Buzzing/Whis
Cowl: Customer InterestRight Hand Windshield - Buzzing/Whistling Noise
Article No.99-4-5
03/08/99
SERVICE PROCEDURE
3.
4.

Warranty Coverage

Screen Repair
DEALER CODING
CONDITION
BASIC PART NO. CODE
> Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 99-4-5 > Mar > 99 > Right Hand Windshield -
Buzzing/Whistling Noise > Page 9083

54018A16 12
OASIS CODES: 108000, 208000, 208300, 208999, 701000, 702000, 702100, 702300
> Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 99-4-5 > Mar > 99 > Right Hand Windshield - B
Cowl: All Technical Service BulletinsRight Hand Windshield - Buzzing/Whistling Noise
Article No.99-4-5
03/08/99
SERVICE PROCEDURE
3.
4.

Warranty Coverage

Screen Repair
DEALER CODING
CONDITION
BASIC PART NO. CODE
> Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 99-4-5 > Mar > 99 > Right Hand
Windshield - Buzzing/Whistling Noise > Page 9089

54018A16 12
OASIS CODES: 108000, 208000, 208300, 208999, 701000, 702000, 702100, 702300
> Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises
Side Doors - Wind Noises
Article No.99-6-5
04/05/99
WINDNOISE - AROUND SIDE DOOR(S) - SERVICETIPS
FORD:1994-99 CROWN VICTORIA, ESCORT, TAURUS1995-99 CONTOUR
LINCOLN-MERCURY:1994-98 MARK VIII1994-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR
LIGHT TRUCK: 1994-97 F-150-350 SERIES1994-99 ECONOLINE, EXPLORER, RANGER1995-99 WINDSTAR19

This TSB article is being republished in its entirety to add model year coverage and specify a standard door weatherstri
ISSUEWindnoise from the side doors may be heard on some vehicles. This may be caused by the door weatherstrip sea
ACTIONDiagnose and repair any windnoise from door weatherstrip concerns using the following Windnoise Service T
E8AZ-19552-A Weatherstrip And Rubber Adhesive

E8AZ-19554-A Instant Adhesive
N806340-S Snap-On Push Pin
SUPERSEDES: 98-18-5
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
> Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind
Noises > Page 9098

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 m
Flanges
are typically used on the body opening where weatherstrip retention fins grab onto each side of the sheet metal flange t
Sheet Metal C-Channels
are typically used on the upper perimeter of the door assembly or body panel to hold the weatherstrip molded base insid
Push Pins
are typically used on the lower perimeter of the door assembly attached to the weatherstrip. They are press fit into shee
Rivets
are used to attach some weatherstrips to the sheet metal body. In cases where a rivet becomes loose, the entire rivet sho
Adhesive Tape
is used to adhere smaller weatherstrip sections to the painted sheet metal surface. All surfaces must be clean and dry be
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 c
3. If sealing contact between the weatherstrip and the door is the root cause of the windnoise, readjust the doors to c
NOTE
WEATHERSTRIP REPAIRS SHOULD NOT CREATE UNACCEPTABLE DOOR CLOSING EFFORTS, WIND
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 weatherstr
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 read
3. Open the door and inspect the seals for degree of compression and possible skips.
Noises > Page 9099

To provide adequate sealing contact, the weatherstrip-to-sheet metal contact should provide a tracing powder footprint
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 w
2.
Review the overall fit of the door to the surrounding panels, and the amount of compression of the weatherstrip a
^ from the quarter panel to the rear door
^ from the rear door to the front door
Noises > Page 9100

^ 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 pane
3.
The door should be adjusted to obtain proper seal compression while maintaining a good door fit. An adjustment
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 th
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 Te
^
As a guideline, if there is insufficient weatherstrip contact of the door, the hinge(s) should be adjusted 2-4 mm
^
Only one hinge should be adjusted at a time. The other tight hinge helps to prevent any drastic door movemen
The amount of movement can be determined by outlining the hinge mounting area on the door prior to adjustm
6.
Finally, the door closing effort should be checked to be sure the seal compression has not increased so much that
> Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noi
Side Doors - Wind Noises
Article No.99-6-5
04/05/99
WINDNOISE - AROUND SIDE DOOR(S) - SERVICETIPS
FORD:1994-99 CROWN VICTORIA, ESCORT, TAURUS1995-99 CONTOUR
LINCOLN-MERCURY:1994-98 MARK VIII1994-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR
LIGHT TRUCK: 1994-97 F-150-350 SERIES1994-99 ECONOLINE, EXPLORER, RANGER1995-99 WINDSTAR19

This TSB article is being republished in its entirety to add model year coverage and specify a standard door weatherstri
ISSUEWindnoise from the side doors may be heard on some vehicles. This may be caused by the door weatherstrip sea
ACTIONDiagnose and repair any windnoise from door weatherstrip concerns using the following Windnoise Service T
E8AZ-19552-A Weatherstrip And Rubber Adhesive

E8AZ-19554-A Instant Adhesive
N806340-S Snap-On Push Pin
SUPERSEDES: 98-18-5
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
> 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 9106

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 m
Flanges
are typically used on the body opening where weatherstrip retention fins grab onto each side of the sheet metal flange t
Sheet Metal C-Channels
are typically used on the upper perimeter of the door assembly or body panel to hold the weatherstrip molded base insid
Push Pins
are typically used on the lower perimeter of the door assembly attached to the weatherstrip. They are press fit into shee
Rivets
are used to attach some weatherstrips to the sheet metal body. In cases where a rivet becomes loose, the entire rivet sho
Adhesive Tape
is used to adhere smaller weatherstrip sections to the painted sheet metal surface. All surfaces must be clean and dry be
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 c
3. If sealing contact between the weatherstrip and the door is the root cause of the windnoise, readjust the doors to c
NOTE
WEATHERSTRIP REPAIRS SHOULD NOT CREATE UNACCEPTABLE DOOR CLOSING EFFORTS, WIND
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 weatherstr
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 read
3. Open the door and inspect the seals for degree of compression and possible skips.

To provide adequate sealing contact, the weatherstrip-to-sheet metal contact should provide a tracing powder footprint
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 w
2.
Review the overall fit of the door to the surrounding panels, and the amount of compression of the weatherstrip a
^ from the quarter panel to the rear door
^ from the rear door to the front door

^ 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 pane
3.
The door should be adjusted to obtain proper seal compression while maintaining a good door fit. An adjustment
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 th
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 Te
^
As a guideline, if there is insufficient weatherstrip contact of the door, the hinge(s) should be adjusted 2-4 mm
^
Only one hinge should be adjusted at a time. The other tight hinge helps to prevent any drastic door movemen
The amount of movement can be determined by outlining the hinge mounting area on the door prior to adjustm
6.
Finally, the door closing effort should be checked to be sure the seal compression has not increased so much that
> Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - C
Inspection

> 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 9118







Table of Contents

SCDS Identification
Note
SCDS Location
^
^



NOTE:

-
^
2.
NOTE:
NOTICE:
NOTICE:

2.
NOTICE:
NOTE:
NOTE:
3. Remove the SCDS.
4.
^ 13 Nm (115 lb-in) - 1994 Capri.
^
8.

10.
11.
NOTICE:
12.













> Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cr

08 > Recall - Cruise Control Switch Jumper Harness > Page 9148

OASIS ACTIVATED?
NOTE:
STOCK VEHICLES
SOLD VEHICLES
^

RELATED DAMAGE
^
^
OWNER REFUNDS
RENTAL VEHICLES
NOTE:



NOTE:
DEALER PRICE

Table of Contents
OVERVIEW
NOTE:
^
NOTE:



2.
NOTE:
NOTICE:
2.
NOTICE:
NOTE:
NOTE:

3. Remove the SCDS.
4.
7.
9.
10.
NOTICE:

11.






> Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 >
Fire Hazard

> 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 9166

> Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15
Deactivation Switch Inspection

> 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 9172







Table of Contents

SCDS Identification
Note
SCDS Location
^
^



NOTE:

-
^
2.
NOTE:
NOTICE:
NOTICE:

2.
NOTICE:
NOTE:
NOTE:
3. Remove the SCDS.
4.
^ 13 Nm (115 lb-in) - 1994 Capri.
^
8.

10.
11.
NOTICE:
12.













> Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 08S01S1 >
Switch Jumper Harness

): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9202

OASIS ACTIVATED?
NOTE:
STOCK VEHICLES
SOLD VEHICLES
^

RELATED DAMAGE
^
^
OWNER REFUNDS
RENTAL VEHICLES
NOTE:



NOTE:
DEALER PRICE

Table of Contents
OVERVIEW
NOTE:
^
NOTE:



2.
NOTE:
NOTICE:
2.
NOTICE:
NOTE:
NOTE:

3. Remove the SCDS.
4.
7.
9.
10.
NOTICE:

11.






> Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07
07V336000: Cruise Control Fire Hazard

): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 9220

> Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 9221

> Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Deactivator Switch
> Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Deactivator Switch > Page 9224

> Cruise Control > Brake Switch (Cruise Control) > Component Information > Service and Repair > Deactivator Switch

REMOVAL
INSTALLATION
> Cruise Control > Brake Switch (Cruise Control) > Component Information > Service and Repair > Deactivator Switch > Page 9227

REMOVAL
NOTE:
INSTALLATION
NOTE:

> Cruise Control > Cruise Control Servo > Component Information > Specifications
Cruise Control Servo: Specifications
Speed Control Servo Nut .....................................................................................................................................................

> Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 9231
Speed Control Servo Assembly

Cruise Control Servo: Service and Repair

REMOVAL
1. Disconnect speed control cable from the throttle body lever. The speed control cable snaps off by pulling upward.2
3. Remove two nuts retaining speed control servo to inner fender apron.4. Remove speed control cable cap from spee

5. Remove speed control cable slug from speed control servo pulley. Gently push cable slug past retaining spring usi
INSTALLATION
8-11 N.m (71-97 Lb-In).

1. Position the bracket to the speed control servo and install three retaining screws. Tighten screws to 2. Make sure th
NOTE:
Incorrect wrapping of speed control cable core wire around speed control servo pulley may result in a high idle
5-7 N.m (45-62 Lb-In).

4. Pull on throttle attachment end of speed control cable to draw cable cap on to speed control servo pulley.5. Insert c
> Cruise Control > Cruise Control Servo Cable > Component Information > Specifications
Cruise Control Servo Cable: Specifications

Speed Control Actuator Cable To Bracket Screw ...............................................................................................................
> Cruise Control > Cruise Control Servo Cable > Component Information > Specifications > Page 9237
Cruise Control Servo Cable: Adjustments
3 mm (0.118 Inch)1. Remove adjuster clip from actuator cable adjuster at accelerator cable bracket.2. Make sure thr
speed control actuator cable.
CAUTION: The speed control actuator cable must not be pulled tight, otherwise speed control may not operate
4. Insert speed control actuator cable retaining clip and snap into place.5. Check that throttle linkage operates freely a
Cruise Control Servo Cable: Service and Repair

REMOVAL
1. Remove nut retaining air cleaner outlet tube.2. Remove screw retaining speed control cable to accelerator cable br
3. Disconnect speed control cable from accelerator cable from the throttle body lever.4. Remove speed control cable
5. Remove speed control actuator cable slug from speed control servo pulley. Gently push actuator cable slug past re
screwdriver.
INSTALLATION
NOTE:
Incorrect wrapping of speed control actuator cable core wire around speed control servo pulley may result in a h
3. Pull on throttle body end of speed control actuator cable to draw cable cap onto speed control servo pulley.4. Alig
until the locking arm engages.
5. Route speed control actuator cable between power brake booster and brake master cylinder reservoir. Position spe
retaining clips.
3-4 N.m (27-35 Lb-In)
6. Snap speed control actuator cable onto throttle body lever and install screw at accelerator cable bracket. Tighten to
1. Make sure that the rubber seal is fully seated onto speed control actuator cable cap.2. Lock speed control actuator
> Cruise Control > Cruise Control Switch > Component Information > Service Precautions

> Cruise Control > Cruise Control Switch > Component Information > Service Precautions > Page 9243
REMOVAL
stored energy.
INSTALLATION

> Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Contr
Cruise Control Deactivation Switch Inspection

> Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake







Table of Contents

SCDS Identification
Note
SCDS Location
^
^



NOTE:

-
^
2.
NOTE:
NOTICE:
NOTICE:

2.
NOTICE:
NOTE:
NOTE:
3. Remove the SCDS.
4.
^ 13 Nm (115 lb-in) - 1994 Capri.
^
8.

10.
11.
NOTICE:
12.













Cruise Control Switch Jumper Harness


OASIS ACTIVATED?
NOTE:
STOCK VEHICLES
SOLD VEHICLES
^

RELATED DAMAGE
^
^
OWNER REFUNDS
RENTAL VEHICLES
NOTE:



NOTE:
DEALER PRICE

Table of Contents
OVERVIEW
NOTE:
^
NOTE:



2.
NOTE:
NOTICE:
2.
NOTICE:
NOTE:
NOTE:

3. Remove the SCDS.
4.
7.
9.
10.
NOTICE:

11.






> Recall 07V336000: Cruise Control Fire Hazard

Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 9301

> Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Bra
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection

> 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 9307







Table of Contents

SCDS Identification
Note
SCDS Location
^
^



NOTE:

-
^
2.
NOTE:
NOTICE:
NOTICE:

2.
NOTICE:
NOTE:
NOTE:
3. Remove the SCDS.
4.
^ 13 Nm (115 lb-in) - 1994 Capri.
^
8.

10.
11.
NOTICE:
12.













08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness

Bulletins for Brake Switch (Cruise Control): > 08S01S1 > Apr > 08 > Recall - Cruise Control Switch Jumper Harness > Page 9337

OASIS ACTIVATED?
NOTE:
STOCK VEHICLES
SOLD VEHICLES
^

RELATED DAMAGE
^
^
OWNER REFUNDS
RENTAL VEHICLES
NOTE:



NOTE:
DEALER PRICE

Table of Contents
OVERVIEW
NOTE:
^
NOTE:



2.
NOTE:
NOTICE:
2.
NOTICE:
NOTE:
NOTE:

3. Remove the SCDS.
4.
7.
9.
10.
NOTICE:

11.






NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard

Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 9355

> Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 9356

> Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Deactivator Switch
> Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Deactivator Switch > Page 9359

> Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service and Repair > Deactivator Switch

REMOVAL
INSTALLATION
> Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service and Repair > Deactivator Switch > Page 9362

REMOVAL
NOTE:
INSTALLATION
NOTE:

> Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service Precautions

> Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service Precautions > Page 9366
REMOVAL
stored energy.
INSTALLATION

> Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Specifications

> Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Specifications > Page 9370
> Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Specifications > Page 9371

REMOVAL
INSTALLATION
> Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Specifications

> Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Specifications > Page 9375
> Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Specifications > Page 9376

REMOVAL
INSTALLATION
> Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation
ABS Light: Description and Operation

The anti-lock brake system uses two warning indicators (BRAKE and ABS) to alert the driver of concerns in the sys
The BRAKE warning indicator will come on for only two reasons:1. If the brake fluid level in the brake master cylin
The amber ABS warning indicator will come on for numerous reasons. It warns the driver that the ABS and traction
Follow the diagnostic procedures step-by-step in order as indicated.Each test is completely independent of the other
> Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation > Page 9381
ABS Light: Testing and Inspection

For testing procedures for this component, refer to Instrument Panel, Gauges and Warning Indicators, Instrument Clust
> Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Customer Interest for Audible Warning Device: >
- High Turning Effort/MIL ON/DTC's Set
Audible Warning Device: Customer InterestIgnition 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 CONTINENTALM

^
ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING
FORD:1998-2002 CROWN VICTORIA, MUSTANG, TAURUS1998-1999 F-250 LD1998-2001 EXPLORER1998-20
LINCOLN:1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR2002 BLACKWOOD
MERCURY:1998-2002 GRAND MARQUIS, SABLE1998-2001 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 func
^
Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes P0500, P1502 and
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 revis
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 pre
NOTE
SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD REMOVAL. REF
> 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 9390

4.
Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while sliding the switch
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
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions W
012113A Replace The 0.3 Hr.
Key-In-Ignition WarningChime Switch
DEALER CODING
BASIC PART NO. CONDITION
CODE
11A127 42
OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000, 208000, 208999, 30100
> Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Audible Warni
Ignition Switch - High Turning Effort/MIL ON/DTC's Set
Audible Warning Device: All Technical Service BulletinsIgnition Switch - High Turning Effort/MIL ON/DTC's
Article No.01-21-13
10/29/01
DRIVEABILITY - DIAGNOSTIC TROUBLE CODES(DTC) P0500, P1502 AND/OR U1039 CONTINENTALM

^
ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING
FORD:1998-2002 CROWN VICTORIA, MUSTANG, TAURUS1998-1999 F-250 LD1998-2001 EXPLORER1998-20
LINCOLN:1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR2002 BLACKWOOD
MERCURY:1998-2002 GRAND MARQUIS, SABLE1998-2001 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 func
^
Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes P0500, P1502 and
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 revis
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 pre
NOTE
SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD REMOVAL. REF
> 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 9396

4.
Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while sliding the switch
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
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions W
012113A Replace The 0.3 Hr.
Key-In-Ignition WarningChime Switch
DEALER CODING
BASIC PART NO. CONDITION
CODE
11A127 42
OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000, 208000, 208999, 30100
> Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions
Audible Warning Device: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9399


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
Warning Chime (Part 1 Of 2)
> Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Electronic Instrument Cluster Tone
Audible Warning Device: Description and OperationElectronic Instrument Cluster Tone

(LCM)With the ignition key in the RUN or ACC position, the safety belt warning chime in the Lighting Control Modu
- when a button on the electronic instrument cluster is pushed.
- in conjunction with visual displays on the electronic instrument cluster.
When ignition switch is in RUN or ACC, power is supplied through Circuit 296 (W/P) to the LCM.
When ignition switch is in RUN or START, power is supplied through Circuit 640 (R/Y) to the LCM.
When appropriate, the electronic instrument cluster Circuit 183 (T/Y) sends a signal to activate the LCM causing
> Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Electronic Instrument Cluster Tone > Page 9409
Audible Warning Device: Description and OperationWarning Chime System

(LCM)The Lighting Control Module warning chime will sound the following warnings:
- key-in-ignition warning
- safety belt warning
- headlamp switch in PARK or HEAD warning
Key-in-Ignition Warning
TheItkey-in-ignition
sounds when the driver chime
warning door isoperates
open or as
ajar with the key in the ignition switch.
follows:-
- It continues to sound until the key is removed or the LH front door is closed.
-
(LCM) When the key is in the ignition, the ignition key warning switch is closed and ground is supplied to th
-
When the driver door is open or ajar, the driver door open warning lamp switch is closed and ground is suppli
Safety Belt Warning

The(LCM)
safety When the ignition
belt warning keyas
operates is follows:-
turned to RUN or START, power is supplied through Circuit 640 (R/Y) to th
- When ignition switch is in RUN or ACC, power is supplied through Circuit 296 (W/P) to LCM.
- 60 seconds
The LCM then supplies power through Circuit 450 (DG/LG) to illuminate the safety belt warning indicator la
-
six secondsIf the LH front safety belt is NOT fastened during this time, the safety belt buckle switch remains
Headlamp Switch On Warning

The(LCM) The Lighting
headlamps Control
on warning Module
operates sounds when the headlamp switch is in PARK or HEAD and the LH fro
as follows:-
- It continues to sound until the headlamp switch is turned OFF or the LH front door is fully closed.
-
When the LH front door is open or ajar, the LH front door open warning lamp switch is closed and power is s
> 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 customer's concern by operating the warning chime system to duplicate the condition.2. Inspect to deter
(15 A) (15
Electrical - A) (15 A) (15 A)check fuse junction panel Fuses 4 , 8 , 13 , 6 .
- check electrical connections for obvious damage, shorts or opens.
(NGS)3. If the inspection reveals obvious concerns that can be readily serviced, correct the concern before continuin
(DLC)
Data Link Connector located beneath the instrument panel to perform DATA LINK DIAGNOSTICS test. If the
5. If self test is passed and no DTCs are retrieved, go to Symptom Chart to continue diagnostics.
(DTCs)6. If DTCs are retrieved, go to Lighting Control Module Diagnostic Trouble Codes Index to continue diagno
See: Diagnostic Trouble Code Descriptions/LCM Diagnostic Trouble Code Index

7. If the lighting control module cannot be accessed by the NGS, go to Pinpoint Test A.
(SBDS (R))Rotunda Service Bay Diagnostic System 418-F001 (001-00001) may also be used to diagnose this sy
> Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9412
Audible Warning Device: Diagnostic Trouble Code Descriptions

Audible Warning Device: Pinpoint Tests
Test Notes
Use Rotunda Digital Volt-Ohmmeter 418-F164 (014-00407) or equivalent to perform pinpoint tests.
B1334-1 - B1334-2
B1340-1 - B1340-6
> Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic

B1352-1 - B1352-4
B1464-1 - B1464-4

A1 - A5

A6 - A11

B1 - B4

C1 - C4
Audible Warning Device: Scan Tool Testing and Procedures


> Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Page 9422
Audible Warning Device: Tools and Equipment
New Generation Star Tester .................................................................................................................................................

> Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Locations

> Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Locations > Page 9426
Speed Chime Module

> Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Description and Operation > With Conventional Instrument Cluster
Charge Lamp/Indicator: Description and OperationWith Conventional Instrument Cluster

Charge indication system consists of the following:
- battery voltage gauge
- generator voltage regulator
- charging system warning indicator
Battery Voltage Gauge
NOTE:
Battery voltage gauge is a part of fuel gauge assembly.
Theindicates battery gauge:-

battery voltage voltage when the ignition switch is in RUN (engine off).
- registers within the band during vehicle operation.
- is not adjustable and should be replaced if inoperative.
Charging System Warning

A red charging system warning indicator is located in the instrument cluster. This indicator glows when there is n
With
If the ignition
system switch OFF,
is working charging
normally, system indicator
the following symbol
conditions is off.
will be present:-
- With ignition switch in RUN (engine off), charging system indicator is on.
- With ignition switch in RUN (engine running), charging system indicator is off.
> Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Description and Operation > With Conventional Instrument Cluster > Page 9431
Charge Lamp/Indicator: Description and OperationWith Electronic Instrument Cluster

Charge indication system consists of the following:
- charging system warning indicator (located in instrument cluster)
- (GEN)Generator /voltage regulator
- circuitry
Charging System Warning
Theischarging
identified by a battery
system warningsymbol.
indicator:-
- indicates battery voltage when the ignition switch is in the RUN position (engine OFF).
With
If the ignition
system switch innormally,
is operating OFF, charge indicator is
the following off.
conditions will be present:-
- With ignition switch in RUN (engine OFF), charge indicator is on.
- With ignition switch in RUN (engine running), charge indicator is off.
> Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions
Cigarette Lighter: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9436


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
Cigar Lighter And Clock
> Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 9444
Cigarette Lighter: Description and Operation

An ash receptacle and cigar lighter knob and elements are located in the center of the instrument panel and in the rear a
The cigar lighter knob and element has a low-resistance heating coil which operates much like the coil used in a portab
-
When the cigar lighter knob and element is pushed completely into the cigar lighter socket and retainer, the circu
-
When sufficient heat is generated, the cigar lighter knob and element overcomes the spring pressure of the bi-met
> Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Service and Repair > Ash Receptacle
Cigarette Lighter: Service and RepairAsh Receptacle
REMOVAL

2. Remove two screws retaining the ash receptacle retainer to the instrument panel.3. Lower forward of instrument p
instrument panel ash receptacle toward front of vehicle to disengage retaining clips.
4. Disconnect ash receptacle wiring at connector.
> Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Service and Repair > Ash Receptacle > Page 9447

5. Remove wiring from ash receptacle bracket. Reach in with a flat-blade screwdriver and lift up on the two spring st
panel ash receptacle from the ash receptacle retainer.
6. Remove cigar lighter knob and element from instrument panel ash receptacle.
INSTALLATION
1. Install cigar lighter knob and element into instrument panel ash receptacle. Install instrument panel ash receptacle
connect wiring harness.
2. Position the ash receptacle clips retainer to the instrument panel and slide rearward to engage retaining clips. Insta
2-3 N.m (18-26 Lb-In)Tighten the screws to .
3. Connect wiring.
> Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Service and Repair > Ash Receptacle > Page 9448
Cigarette Lighter: Service and RepairCigarette Lighter
REMOVAL
1. Disconnect the battery ground cable.2. Open instrument panel ash receptacle. Remove cigar lighter knob and elem
INSTALLATION
1. To install, reverse Removal procedure.
> Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions
Clock: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 9453


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
Clock
Cigar Lighter And Clock
> Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Page 9462
Clock: Description and Operation
The electric clock:

- 12-hourdisplays time in a format.
- illuminates with ignition switch in ACC or RUN.
- dims when headlamps are on.
- is located in instrument panel to the right of the instrument cluster.
Setting Time
1. Press and hold H button until desired hour is displayed.2. Press and hold M button until desired minute is displ
> Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Clock: Initial Inspection and Diagnostic Overview
1. Verify the customer concern by operating the clock to duplicate the condition.2. Inspect to determine if one of the
Check for- obvious damage to the clock

Mechanical
Electrical -
Check
(15 system
A)fuse fuses-
junction panel and 6
3. If inspection reveals obvious concern(s) that can be readily identified, repair as identified.4. If the concern(s) rema

> Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9465
> Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9466
Clock: Pinpoint Tests
Test Notes
Use 73 Digital Multimeter 105-R0051 or equivalent to perform the Pinpoint Test.
A1 - A10
> Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Page 9467
Clock: Service and Repair

REMOVAL
1. Remove instrument panel finish panel.2. Disconnect clock electrical connector.3. Remove two screws retaining el
INSTALLATION
> Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Page 9468
Clock: Tools and Equipment

73 Digital Multimeter ..........................................................................................................................................................
> Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarmin

WARNING:^
air bag module.
one minute (ECS)

WARNING:^
air bag module.

> Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Arming and Disarming > Page 9474

> Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarmin

> Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams
Message Center Switch Assembly

> Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation > With Conventional Instrument Cluster
Fuel Gauge: Description and OperationWith Conventional Instrument Cluster

The fuel level indication system consists of the following components:
- fuel pump module (located in fuel tank)
- low fuel level warning switch with low fuel warning (located on the back of instrument cluster)
- fuel gauge (located in instrument cluster)
Fuel Gauge
NOTE:
The magnetic fuel gauge has the following features:-

The coils form a magnetic field which varies in direction according to the variable resistance of the fuel level
- The pointer position varies proportionately to the current flow. There is no adjustment, calibration or mainten
NOTE:
Theislow
designed to reduce
fuel level fuel
switch:-
Fuel Pump Module

TheAfuel
variable
pumpresistor
moduleisconsists
-
- When fuel level is low, resistance in the fuel level sender is low and movement of the gauge indicator pointer
> Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation > With Conventional Instrument Cluster > Page 9483
Fuel Gauge: Description and OperationWith Electronic Instrument Cluster
Fuel Gauge
TheFuel
fuel level
gaugeisoperates
displayed inon
thea following
digital barmanner:-
gauge using 8 bars top to bottom.
-
Fuel70remaining
liters (18isgal) For fuelinlevels
displayed greater than , thegauge.-
the fuel/temperature letter F (full) is displayed.
- 3 liters (1 gal)For fuel levels less than , the letter E (empty) is displayed.
- (E/M)
Liter or gallon values are selected by the English/Metric button, in the message center switch module, located
- The digital displays are based on a varying current flow from the fuel level sensor.
Theprove out sequence-on/off/on.

fuel pump symbol is always on except during:-
- low fuel level warning-the gas pump symbol flashes when approximately one-eighth of a tank of fuel remains
Diagnostic Bars
Diagnostic bars perform the following functions:-

168 ohms 11 ohms
Either
When onlyanthe
open
top or short
and circuit
bottom twoisbars
present.
appear on the fuel gauge, this indicates that the resistance of the fuel l
- "CO" for circuit open or "CS" for circuit short will be displayed if function is selected.
- 30 seconds
30-second
There is a built-in delay of approximately from the time the circuit open or short occurs until the diagnostic b
A low fuel level warning is given by a flashing gas pump symbol when the fuel remaining is approximately one-e
Fuel Level Sender
TheWhen the fuelof
the level is low
of an and number
attached of litfuel
tank.-
> Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation > Page 9484
Fuel Gauge: Service and Repair

NOTE: The battery voltage gauge is serviceable as part of fuel gauge/low fuel level warning switch service kit.
REMOVAL
1. Disconnect battery ground cable.2. Remove instrument cluster.
CAUTION: The gauges are calibrated at the factory. Excessive rough handling could disturb the calibration. Do
3. Remove screws retaining instrument cluster back plate and remove instrument cluster main lens and instrument cl
INSTALLATION
1. To Install, reverse removal procedure.
> Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Electronic Instrument Cluster

Fuel Level Sender
TheWhen the fuelof
the level is low
of an and number
attached of litfuel
tank.-
> Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Electronic Instrument Cluster > Page 9489
NOTE:
Theislow
designed to reduce
fuel level fuel
switch:-
Fuel Pump Module

TheAfuel
variable
pumpresistor
moduleisconsists
-
-
> Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Air Bag(s) Arming and Disarming > System Information > Service and Repair

WARNING:^
air bag module.
one minute (ECS)

WARNING:^
air bag module.

> Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Air Bag(s) Arming and Disarming > System Information >
Service and Repair > Arming and Disarming > Page 9495

> Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Air Bag(s) Arming and Disarming > System Information > Service and Repair

> Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Instrument Panel Bulb > Component Information > Service and Repair > Conv
Instrument Panel Bulb: Service and RepairConventional Instrument Cluster
REMOVAL
1. Disconnect battery ground cable.2. Remove instrument cluster.3. Remove bulb by one of the following methods:
a. For twist-in bulbs, gently grasp the bulb, push lightly while turning counterclockwise and remove the bulb.b. F
edge for leverage.
WARNING: BULBS ARE PRESSURIZED AND MAY SHATTER IF IMPROPERLY HANDLED. WEA
INSTALLATION
> Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Instrument Panel Bulb > Component Information > Service and Repair > Conv
9501
Instrument Panel Bulb: Service and RepairElectronic Instrument Cluster

REMOVAL
1. Remove lens cover, if equipped.2. Remove bulb by one of the following methods:
a. For twist-in bulbs, gently grasp the bulb, push lightly while turning counterclockwise and remove the bulb.b. F
edge for leverage.
INSTALLATION
> Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Instrument Panel Circuit Board > Component Information > Service and Repai
Instrument Panel Circuit Board: Service and Repair

REMOVAL
1. Disconnect battery ground cable.2. Remove instrument cluster assembly.3. Remove illumination and instrument p
INSTALLATION
1. Place printed circuit on instrument cluster and install indicator and illumination miniature bulbs.2. Install the fiftee
> Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Instrument Panel Control Module > Component Information > Description and

- ABS indicator.

> Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Instrument Panel Control Module > Component Information > Testing and Insp
Diagnostic Overview

Electrical -
Fuse(15
junction
A)Fusepanel:-
13 .
- Circuit wiring.
Procedures
> Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Instrument Panel Control Module > Component Information > Testing and Insp
Diagnostic Overview > Page 9510
> Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Instrument Panel Control Module > Component Information > Service and Rep

REMOVAL
INSTALLATION
> Instrument Panel, Gauges and Warning Indicators > Instrument Cluster <--> [Instrument Cluster / Carrier] > Instrument Panel Control Module > Component Information > Service and Rep

REMOVAL
INSTALLATION
> Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation > With Conventional Instrument Cluster
Low Fuel Lamp/Indicator: Description and OperationWith Conventional Instrument Cluster

The fuel level indication system consists of the following components:
- fuel pump module (located in fuel tank)
- low fuel level warning switch with low fuel warning (located on the back of instrument cluster)
- fuel gauge (located in instrument cluster)
Fuel Gauge
NOTE:
The magnetic fuel gauge has the following features:-

The coils form a magnetic field which varies in direction according to the variable resistance of the fuel level
- The pointer position varies proportionately to the current flow. There is no adjustment, calibration or mainten
NOTE:
Theislow
designed to reduce
fuel level fuel
switch:-
Fuel Pump Module

TheAfuel
variable
pumpresistor
moduleisconsists
-
- When fuel level is low, resistance in the fuel level sender is low and movement of the gauge indicator pointer
> Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation > With Conventional Instrument Cluster > Page 9518
Low Fuel Lamp/Indicator: Description and OperationWith Electronic Instrument Cluster
Fuel Gauge
TheFuel
fuel level
gaugeisoperates
displayed inon
thea following
digital barmanner:-
gauge using 8 bars top to bottom.
-
Fuel70remaining
liters (18isgal) For fuelinlevels
displayed greater than , thegauge.-
the fuel/temperature letter F (full) is displayed.
- 3 liters (1 gal)For fuel levels less than , the letter E (empty) is displayed.
- (E/M)
Liter or gallon values are selected by the English/Metric button, in the message center switch module, located
- The digital displays are based on a varying current flow from the fuel level sensor.
Theprove out sequence-on/off/on.

fuel pump symbol is always on except during:-
- low fuel level warning-the gas pump symbol flashes when approximately one-eighth of a tank of fuel remains
Diagnostic Bars
Diagnostic bars perform the following functions:-

168 ohms 11 ohms
Either
When onlyanthe
open
top or short
and circuit
bottom twoisbars
present.
appear on the fuel gauge, this indicates that the resistance of the fuel l
- "CO" for circuit open or "CS" for circuit short will be displayed if function is selected.
- 30 seconds
30-second
There is a built-in delay of approximately from the time the circuit open or short occurs until the diagnostic b
A low fuel level warning is given by a flashing gas pump symbol when the fuel remaining is approximately one-e
Fuel Level Sender
TheWhen the fuelof
the level is low
of an and number
attached of litfuel
tank.-
> Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation > Page 9519
Low Fuel Lamp/Indicator: Service and Repair

NOTE:
The low fuel warning switch is serviceable only as part of the fuel gauge low fuel level warning switch kit. The gauge
REMOVAL
1. Remove instrument cluster.2. Grasp instrument cluster printed circuit on outside far edges. Avoid touching circuit
INSTALLATION
1. To install, position low fuel level warning switch in guides, line up terminals over center of instrument cluster prin
push until low fuel level warning switch clicks in place.
2. Install instrument cluster.
> Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation
> Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation > Conventional Cluster
Odometer: Description and OperationConventional Cluster

The odometer:
- is integral to the speedometer.
- is driven by the vehicle speed sensor input signal.
- registers up to 999,999 and then resets to 000000.
Odometer Replacement
The mileage on replacement speedometer/odometers cannot be reset by the technician. A speedometer, preset to
Trip Odometer
Trip odometer is housed within speedometer below the primary odometer.
The trip odometer can be reset by pushing the reset shaft that extends from speedometer.
> Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation > Conventional Cluster > Page 9527
Odometer: Description and OperationElectronic Cluster

The odometer operates in the following manner:
- Displays either miles or kilometers by pressing the E/M button.
- Displays seven digits, with the last digit in tenths of a unit.
-
The000000.5
odometer925,691.9 milesThe
range is limited English
by the units range
instrument from
cluster to . (The
memory display will freeze at this value.)
space.-
- 000000.8 858,993.4 km 000000.0
622113.6 km 925,691.9The metric range is from to where the value will roll over to and continue accumula
-
If the mileage on the original odometer is unknown, the replacement odometer will show no mileage. Then the S
-
If the actual vehicle mileage can be verified, an authorized service center can program the replacement odometer
-
If a condition exists where the electronic instrument cluster cannot read a valid odometer memory from the non-v
> Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation > Page 9528
Odometer: Service and Repair

CAUTION:
During service, it is important to keep the speedometer face-up as speedometer function will be affected by storage in
NOTE:
The speedometer mileage cannot be reset by the technician. A speedometer preset to the correct mileage is available t
REMOVAL
1. Disconnect battery ground cable.2. Remove instrument cluster.3. Remove seven screws retaining instrument cluste
INSTALLATION
1. Position speedometer to the instrument cluster back plate and install.2. Position instrument cluster mask and instru
> Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications

> Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications > Page 9532
Oil Pressure Switch

Theisoil
threaded
switch:-
> Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > With Conventional Instrument Cluster
The90 degreeItgauge
magnetic consists
has of
thetwo primaryfeatures:-
following coils, one of which is wound at a angle to the other one.
Oil Pressure Switch

Theisoil
threaded
switch:-
> Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > With Conventional Instrument Cluster
Theoil
oilpressure
indication engine.

Oil Pressure Switch
> Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Locations

> Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Locations > Page 954
Speed Chime Module

> Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Description and Operation

- ABS indicator.

> Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Testing and Inspection > Initia

Electrical -
Fuse(15
junction
A)Fusepanel:-
13 .
- Circuit wiring.
Procedures
> Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Testing and Inspection > Initia
> Page 9548
> Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Service and Repair > Indicato

REMOVAL
INSTALLATION
> Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Service and Repair > Indicato

REMOVAL
INSTALLATION
> Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Electronic Ins

Fuel Level Sender
TheWhen the fuelof
the level is low
of an and number
attached of litfuel
tank.-
> Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Electronic Ins
NOTE:
Theislow
designed to reduce
fuel level fuel
switch:-
Fuel Pump Module

TheAfuel
variable
pumpresistor
moduleisconsists
-
-
> Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Adjustments
1.4 kg (3 lbs.)
adjustment.
> Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Adjustments > Page 9561

REMOVAL
INSTALLATION
> Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Specifications > Speedometer Drive/Driven Gear Usage
Speedometer Head: SpecificationsSpeedometer Drive/Driven Gear Usage

> Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Specifications > Speedometer Drive/Driven Gear Usage > Page 9566
> Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation > With Conventional Instrument Cluster
Speedometer Head: Description and OperationWith Conventional Instrument Cluster

(VSS)The electromechanical speedometer receives speed information from the transmission-mounted Vehicle Speed S
The circuit electronics are calibrated to drive the speedometer pointer to a location in proportion to the frequency of the
> Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation > With Conventional Instrument Cluster > Page 9569
Speedometer Head: Description and OperationWith Electronic Instrument Cluster

NOTE:
The symbol KPH signifies a metric speed display and the symbol MPH signifies an English unit speed display. Units
The speedometer display:

-
(VSS)provides speed information based on a speed/distance pulse signal (specific number of pulses per mile) fro
- 193 kph (120 mph)is limited to a maximum of .
> Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Service and Repair > Conventional Instrument Cluster
Speedometer Head: Service and RepairConventional Instrument Cluster

CAUTION:
During service, it is important to keep the speedometer face-up as speedometer function will be affected by storage in
NOTE:
The speedometer mileage cannot be reset by the technician. A speedometer preset to the correct mileage is available t
REMOVAL
1. Disconnect battery ground cable.2. Remove instrument cluster.3. Remove seven screws retaining instrument cluste
INSTALLATION
1. Position speedometer to the instrument cluster back plate and install.2. Position instrument cluster mask and instru
> Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Service and Repair > Conventional Instrument Cluster > Page 9572
Speedometer Head: Service and RepairElectronic Instrument Cluster

NOTE:
The electronics within the instrument cluster are NOT serviceable. For a confirmed electronic failure, return the entire
Federal law requires that the odometer in any replacement speedometer/odometer must register the same mileage as tha
If the actual vehicle mileage cannot be verified, the service center will supply a speedometer/odometer or odometer mo
REMOVAL
10. Remove
assembly
instrument
forward. panel finish panel carefully so not to scratch the instrument cluster lens.11. Disconnect electri
13. Remove four screws retaining instrument cluster. Pull instrument cluster out and disconnect electrical connectors
INSTALLATION
3-4 N.m (27-35 Lb-In)1. Follow removal procedure in reverse order.2. Tighten the instrument panel finish panel reta
> Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation > With Conventional Instrument Cluster


coils of wireGauge
calledhas
thethe
bobbin. One coil
features:-
-
> Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation > With Conventional Instrument Cluster > Page 9577


ThisHgauge
-
13,000 ohms 200 ohms 13,000 ohms
-
Diagnostic Bars
200 ohms
When the
Diagnostic topontwo
bars thisand bottom
gauge two bars
coolant gauge,
temperature a short
sender circuit
is lower thanmay
thebe
o
Fail Safe Cooling
(124C)
Allthe
Once eight
is met:-
(166C)
Allthe
is met:-
is mounted
sender:-
-
> Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation > Page 9578

REMOVAL
INSTALLATION
> Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Description and Operation > With Conventional Instrument Cluster
> Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Description and Operation > With Conventional Instrument Cluster > Page 9


ThisHgauge
-
13,000 ohms 200 ohms 13,000 ohms
-
Diagnostic Bars
200 ohms
When the
Diagnostic topontwo
bars thisand bottom
gauge two bars
coolant gauge,
temperature a short
sender circuit
is lower thanmay
thebe
o
Fail Safe Cooling
(124C)
Allthe
Once eight
is met:-
(166C)
Allthe
is met:-
is mounted
sender:-
-
> Instrument Panel, Gauges and Warning Indicators > Transmission Mode Indicator - A/T > Component Information > Service and Repair > Disassembly and Assembly

DISASSEMBLY
forward.
range indicator.
ASSEMBLY
> Instrument Panel, Gauges and Warning Indicators > Transmission Mode Indicator - A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 9588

REMOVAL
INSTALLATION
> Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Locations
Transmission Shift Position Indicator Lamp: Locations

The transmission range indicator lamp is located in the instrument cluster.
> Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Locations > Page 9592
Transmission Shift Position Indicator Lamp: Description and Operation

The transmission range indicator is located in instrument cluster, below speedometer.
> Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Locations > Page 9593
Transmission Shift Position Indicator Lamp: Service and Repair

REMOVAL
INSTALLATION
> Lighting and Horns > Ambient Light Sensor > Component Information > Specifications

> Lighting and Horns > Ambient Light Sensor > Component Information > Specifications > Page 9598
REMOVAL
INSTALLATION
> Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations
Transmission View

> Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 9605

> 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 D
Brake Lamp: Customer InterestA/T - Inadvertent Shift Interlock Disabling
Article No.02-17-6
09/02/02
LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK
FORD:1992-1993 FESTIVA1992-1994 TEMPO1992-1997 THUNDERBIRD1992-2003 CROWN VICTORIA, ESCO
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 lam
ACTION
As appropriate, dealers should

MERCURY:1992-1994 advise ownersCOUGAR1992-1999
TOPAZ1992-1997 (including corporate,TRACER1992-2003
municipal, and police agencies) that anyGRAND
SABLE1993-2003 vehicle tha
MA
> 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 9614

(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 connectio

> 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 Sh
Brake Lamp: All Technical Service BulletinsA/T - Inadvertent Shift Interlock Disabling
Article No.02-17-6
09/02/02
ISSUE
ACTION

MA
> 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 9620


> Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions
Brake Lamp: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9623


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
Brake Lamp: Electrical Diagrams

Turn/Stop/Hazard Lamps


> Lighting and Horns > Brake Lamp > Component Information > Diagrams > Page 9633
Brake Lamp: Description and Operation

Stoplamps are mounted in the same housings as the rear lamps.
Stoplamp functions are performed by double filament bulbs:

-
The low power filaments are dedicated to the rear lamp operation and are continuously on when the headlamp sw
- Stoplamp function lights the high power filaments when the driver applies the brake pedal.
> Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis
Brake Lamp: Flow of Diagnosis
1. Verify the customer's original concern by operating the brake pedal to duplicate the condition.2. Inspect to determ
Mechanical
- (BPP)Damaged Brake Pedal Position switch.
Circuitry
- (15 A) (15 A) (15 A) (15 A) (18 A) (15 A)Open fuse function panel, Fuse 1 , Fuse 5 , Fuse 6 , Fuse 8 circuit
- Damaged connectors.
3. If the inspection reveals obvious concern(s) that can be readily identified, service as required.4. If the concern(s) r
> Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9636
Brake Lamp: Initial Inspection and Diagnostic Overview
1. Verify the customer's original concern by operating the brake pedal to duplicate the condition.2. Inspect to determ
Mechanical
- (BPP)Damaged Brake Pedal Position switch.
Circuitry
- (15 A) (15 A) (15 A) (15 A) (18 A) (15 A)Open fuse function panel, Fuse 1 , Fuse 5 , Fuse 6 , Fuse 8 circuit
- Damaged connectors.
Brake Lamp: Pinpoint Tests
Test Notes
Use 73 Digital Multimeter 105-R0051 or equivalent to perform pinpoint tests.
BA1 - BA8
BB1 - BB2
> Lighting and Horns > Brake Pedal Position Switch (BPP) <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Customer Interest: > 02-13-6 > Jul > 02 > S
Article No.02-13-6
07/08/02
ISSUE
ACTION
Parts Block

BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
> Lighting and Horns > Brake Pedal Position Switch (BPP) <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Customer Interest: > 02-13-6
> Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 9647

3.
> Lighting and Horns > Brake Pedal Position Switch (BPP) <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10
Driveability Symptoms
Article No.98-23-10
11/23/98
SERVICE TIP

> Lighting and Horns > Brake Pedal Position Switch (BPP) <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > All Technical Service
Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 9653

voltage at idle.
NOTE
Symptoms
^ Lack of Power
^ Buck/Jerk
OBDII DTCs
OBDI DTCs
NOTE:
> Lighting and Horns > Brake Pedal Position Switch (BPP) <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > All Technical Service
Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 9654

1.
NOTE
NOTE
2.
3.
4.
NOTE
> Lighting and Horns > Brake Pedal Position Switch (BPP) <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pedal
Oct > 03 > Customer Interest for Brake Pedal Position Switch (BPP): > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative
Article No.02-13-6
07/08/02
ISSUE
ACTION
Parts Block

BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
> Lighting and Horns > Brake Pedal Position Switch (BPP) <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins
for Brake Pedal Position Switch (BPP): > 03-20-3 > Oct > 03 > Customer Interest for Brake Pedal Position Switch (BPP): > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock -

3.
> Lighting and Horns > Brake Pedal Position Switch (BPP) <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Me
Article No.02-13-6
07/08/02
ISSUE
ACTION
Parts Block

BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
> Lighting and Horns > Brake Pedal Position Switch (BPP) <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins
for Air Flow Meter/Sensor: > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 9670

3.
> Lighting and Horns > Brake Pedal Position Switch (BPP) <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Page 9671

> Lighting and Horns > Brake Pedal Position Switch (BPP) <--> [Brake Light Switch] > Component Information > Technical Service Bulletins > Page 9672

Engine View
> Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 >
Disabling
Center Mounted Brake Lamp: Customer InterestA/T - Inadvertent Shift Interlock Disabling
Article No.02-17-6
09/02/02
ISSUE
ACTION

MA
> 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 9681


> Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Mounted Brake Lamp: > 02-17-6
Interlock Disabling
Center Mounted Brake Lamp: All Technical Service BulletinsA/T - Inadvertent Shift Interlock Disabling
Article No.02-17-6
09/02/02
ISSUE
ACTION

MA
> 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 9687


> Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Page 9688
Center Mounted Brake Lamp: Description and Operation

The rear hi-mount lamp is mounted in the rear window area.
> Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Page 9689
Center Mounted Brake Lamp: Service and Repair
REMOVAL
1. Lift up the rear hi-mount lamp by gently lifting with a flat-blade screwdriver. Disconnect the wiring connector.2. C
INSTALLATION
1. Position mounting pins of rear hi-mount lamp to align with pushpin holes. Press rear hi-mount lamp down until it
> Lighting and Horns > Cornering Lamp > Component Information > Specifications
Cornering Lamp: Specifications
Side Marker and Cornering Lamp Retaining Screws ..........................................................................................................

> Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions
Cornering Lamp: Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9695


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
Cornering Lamps
> Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Page 9703
Cornering Lamp: Description and Operation

CORNERING LAMP SWITCH
The cornering lamps are supplied power from the turn signal circuit. When a left or right turn is signaled, the corneri
> Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow of Diagnosis
Cornering Lamp: Flow of Diagnosis
1. Verify the customer's concern by operating the cornering lamps to duplicate the condition.2. Inspect to determine i
Mechanical
- Damaged headlamp switch.
Circuitry
- Bulb burned out.
- (15 A) (18 A)Damaged fuse junction panel Fuse 13 , circuit Breaker 12 .
> Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9706
Cornering Lamp: Initial Inspection and Diagnostic Overview
1. Verify the customer's concern by operating the cornering lamps to duplicate the condition.2. Inspect to determine i
Mechanical
Circuitry
- Bulb burned out.
- (15 A) (18 A)Damaged fuse junction panel Fuse 13 , circuit Breaker 12 .
Cornering Lamp: Pinpoint Tests
Test Notes
DA1 - DA4
> Lighting and Horns > Cornering Lamp > Component Information > Testing and Inspection > Page 9709
Cornering Lamp: Service and Repair
REMOVAL
1. Remove two nuts and one screw retaining cornering lamp to front fender.2. Pull cornering lamp away from front f
INSTALLATION
> Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Description and Operation
Glove Box Lamp: Description and Operation

The glove compartment lamp system consists of:
- a glove compartment lamp switch and wire and miniature bulb assembly.
- circuit wiring and circuit protection.
Opening the glove compartment door closes the switch which provides power to the glove compartment lamp switch an
> Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Description and Operation > Page 9714
Glove Box Lamp: Service and Repair

REMOVAL
The glove compartment lamp switch and wire is mounted above the glove compartment. The glove compartment
1. Disconnect wiring.2. Remove one screw retaining glove compartment lamp switch and wire to instrument panel.
INSTALLATION
1. Place the glove compartment lamp switch and wire in position, install retaining screw and adjust glove compartme
2-3 N.m (18-26 Lb-In)Tighten screw to .
2. To replace miniature bulb, pull out with thumb and finger. Install new miniature bulb by pressing into socket.
> Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information > Service and Repair
REMOVAL
INSTALLATION
> Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations

Engine View
> Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations > Page 9722

> Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Service and Repair > Control Module
REMOVAL
INSTALLATION
> Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Service and Repair > Control Module > Page 9725
REMOVAL
INSTALLATION
> Lighting and Horns > Dome Lamp > Component Information > Description and Operation > Dome Lamp
Dome Lamp: Description and OperationDome Lamp
The interior lamp is actuated by:

- opening front or rear door (interior lamp switch).
- pushing the headlamp switch knob.
> Lighting and Horns > Dome Lamp > Component Information > Description and Operation > Dome Lamp > Page 9730
Dome Lamp: Description and OperationDome/Map Combination Lamp
The two dome/map lamps are located on each side of the interior lamp. The map lamps are each operated independentl
> Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Dome Lamp Housing
Dome Lamp: Service and RepairDome Lamp Housing

REMOVAL
1. Rotate both interior lamp lenses to stop, then continue to push until interior lamp goes beyond stop and is in the ve
INSTALLATION
1. Connect wiring connector.2. Position interior lamp into place.3. Install the screws.4. Rotate interior lamp lenses to
> Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Dome Lamp Housing > Page 9733
Dome Lamp: Service and RepairDome Lamp Lens
REMOVAL
1. Using a thin flat-bladed screwdriver, pry the interior lamp lens from the interior lamp.
INSTALLATION
1. Snap interior lamp lens back into interior lamp.
> Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Exterior Lighting Module: > 02-9-7 > May > 02 > Turn Si
Article No.02-9-7
05/13/02
SERVICE PROCEDURE
1
3.
> Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Exterior Lighting Module: > 02-9-7 > May
> 02 > Turn Signals - Intermittent Rapid Flashing > Page 9742


SUPERSEDES: 01-21-3
DEALER CODING
CONDITION
BASIC PART NO. CODE
> Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Exterior Lighting Module: > 02-9-7 > May
> 02 > Turn Signals - Intermittent Rapid Flashing > Page 9743

13C788 42
OASIS CODES: 201000, 201100, 201200, 206000

> Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exterior Lighting Module: > 02-9-7 > May >
Rapid Flashing
Article No.02-9-7
05/13/02
SERVICE PROCEDURE
1
3.
> Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exterior Lighting Module: >
02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing > Page 9749


SUPERSEDES: 01-21-3
DEALER CODING
CONDITION
BASIC PART NO. CODE
> Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exterior Lighting Module: >
02-9-7 > May > 02 > Turn Signals - Intermittent Rapid Flashing > Page 9750

13C788 42
OASIS CODES: 201000, 201100, 201200, 206000

> Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Locations > Police Option Emergency Flasher Relay #1

> Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Locations > Police Option Emergency Flasher Relay #1 > Page 9756

> Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Hazard Flasher
Hazard Warning Flasher: LocationsHazard Flasher

1996 Crown Victoria shown, others similar
The Hazard Flasher output is provided by the Lighting Control Module, which is located behind LH side of the instrum
> Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Hazard Flasher > Page 9761
Hazard Warning Flasher: LocationsPolice Option Only
Front Flasher
The Police Option Front Flasher is located at the right rear of the engine compartment.
Rear Flasher
The Police Option Rear Flasher is located at the center rear of the trunk.
> Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations
> Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9767


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:

> Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 9776

> Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).
See: Headlamp/Testing and Inspection/Component Tests and General Diagnostics/Diagnostic Trouble Code(s)/Lightin
> Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9779

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).

Part 1 Of 3

Part 2 Of 3
Part 3 Of 3
Part 1 Of 2

Part 2 Of 2
Part 1 Of 2
Part 2 Of 2
Flow of Diagnosis
NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)

-
IGNSW
Open Power(50A)
- STR/ALT (30A).

Part 1 Of 3
Part 2 Of 3
Part 3 Of 3

Part 1 Of 2
Part 2 Of 2
Part 1 Of 2

Part 2 Of 2




Pinpoint Test G1






> Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Page 9797
REMOVAL
INSTALLATION
> Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Specifications
Headlamp Bulb: Specifications

TRADE NUMBER 9007
Rated Current Watts
4.30 A Low Beam 55 Low Beam
5.08 A High Beam 65 High Beam
> Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Specifications > Page 9802
Headlamp Bulb: Service and Repair

REMOVAL
1. Turn headlamp switch to OFF position.
WARNING: THE HALOGEN HEADLAMP BULB CONTAINS GAS UNDER PRESSURE. THE HALO
NOTE:
A properly aimed headlamp normally does not need to be re-aimed after installation of a headlamp bulb and reta
2. Lift hood and locate headlamp bulb and retainer installed in rear of headlamp.3. Disconnect headlamp dash panel
5. Carefully remove headlamp bulb and retainer from socket in headlamp by gently pulling straight out of socket. Do
retainer during removal.
INSTALLATION
1. Insert the glass envelope of headlamp bulb and retainer into headlamp while aligning the locking tabs.2. Rotate he
> Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations
> Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9808


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:

> Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 9817

Theturn signal.
- hazard warning.
- cornering lamps.
- headlamp dimmer.
NORMAL OPERATION

moving thethe
the turn
FLASH-TO-PASS
NOTE:

> Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).
See: Testing and Inspection/Component Tests and General Diagnostics/Diagnostic Trouble Code(s)/Lighting Control M
> Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9820

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).

Part 1 Of 3

Part 2 Of 3
Part 3 Of 3
Part 1 Of 2

Part 2 Of 2

Flow of Diagnosis
NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)

-
IGNSW
Open Power(50A)
- STR/ALT (30A).

Part 1 Of 3
Part 2 Of 3
Part 3 Of 3

Part 1 Of 2
Part 2 Of 2





Pinpoint Test G1






> Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 9838
REMOVAL
INSTALLATION
> Lighting and Horns > Headlamp > Headlamp Lens > Component Information > Service and Repair > Cleaning and Inspection
Headlamp Lens: Service and RepairCleaning and Inspection
Clean headlamps by spraying with Ultra-Clear Spray Glass Cleaner E4AZ-19C507-AA or equivalent meeting Ford spe
> Lighting and Horns > Headlamp > Headlamp Lens > Component Information > Service and Repair > Cleaning and Inspection > Page 9843
Headlamp Lens: Service and RepairHeadlamp Assembly
REMOVAL
1. Turn headlamp switch to the OFF position.
WARNING: THE HALOGEN HEADLAMP BULB CONTAINS GAS UNDER PRESSURE. THE HEAD
NOTE: The headlamp on this vehicle does not need replacement when the headlamp bulb and retainer burn out.
2. Disconnect headlamp dash panel junction wire from headlamp bulb and retainer by grasping wires firmly and snap
NOTE: Use snap-ring pliers to spread headlamp mounting clips, then pull straight upward to disengage.
4. Remove headlamp from vehicle.
INSTALLATION
1. Follow removal procedure in reverse order.2. Aim headlamp under Adjustments.
> Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9848


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:


> Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 9858
-
-



REMOVAL
INSTALLATION
> Lighting and Horns > Horn > Horn Relay > Component Information > Locations

Engine View
> Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 9867

> Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 9868

REMOVAL
INSTALLATION
> Lighting and Horns > Horn > Horn Switch > Component Information > Description and Operation

> Lighting and Horns > Horn > Horn Switch > Component Information > Description and Operation > Page 9872

REMOVAL
INSTALLATION
> Lighting and Horns > Lighting Control Module (LCM) <--> [Lamp Control Module] > Component Information > Locations

> Lighting and Horns > Lighting Control Module (LCM) <--> [Lamp Control Module] > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Lighting and Horns > Lighting Control Module (LCM) <--> [Lamp Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page
9878

9879

System Diagrams
9880

Grounds Diagrams
9881

ELECTRICAL SYMBOLS
Electrical Symbols
9882

Electrical Symbols
VACUUM SYMBOLS
9883

Vacuum Symbols

BK
BL
BR
9884

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Lighting and Horns > Lighting Control Module (LCM) <--> [Lamp Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9885

9886

9887

> Lighting and Horns > Lighting Control Module (LCM) <--> [Lamp Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9888

9889

9890

> Lighting and Horns > Lighting Control Module (LCM) <--> [Lamp Control Module] > Component Information > Diagrams > Page 9891
> Lighting and Horns > Lighting Control Module (LCM) <--> [Lamp Control Module] > Component Information > Diagrams > Page 9892

REMOVAL
INSTALLATION
> Lighting and Horns > License Plate Lamp > Component Information > Description and Operation
License Plate Lamp: Description and Operation

The license lamps :
- are located in the luggage compartment door.
- have serviceable miniature bulbs.
- power is provided through the lighting control module and Circuit 14 (BR) when the headlamp switch is in either
- (15 A) (18 A)power is provided through Fuse 4 and Circuit Breaker 12 in the fuse junction panel.
- ground is provided through Circuit 57 (BK).
- are lit whenever the headlamp switch is in the PARK or HEAD position.
> Lighting and Horns > License Plate Lamp > Component Information > Description and Operation > Page 9896
License Plate Lamp: Service and Repair
REMOVAL
1. Open luggage compartment door.2. Using a Phillips-head screwdriver, remove two plastic rivets retaining lamp to
INSTALLATION
> Lighting and Horns > Map Light > Component Information > Description and Operation
Map Light: Description and Operation
Interior lamp is located at the top and center of the back window glass in the roof headlining. The interior lamp is contr
> Lighting and Horns > Map Light > Component Information > Service and Repair > Map Lamp Housing
Map Light: Service and RepairMap Lamp Housing

REMOVAL
1. Remove the three screws that retain the interior lamp to its mounting surface.2. Lower the courtesy I map lamp bra
INSTALLATION
> Lighting and Horns > Map Light > Component Information > Service and Repair > Map Lamp Housing > Page 9902
Map Light: Service and RepairMap Lamp Lens

REMOVAL
1. Rotate interior lamp lens to stop.2. Insert thin-bladed screwdriver in slot on side of interior lamp lens and twist scr
INSTALLATION
1. Position interior lamp lens to interior lamp (interior lamp lens will only fit one way) and push to snap in interior la
> Lighting and Horns > Marker Lamp > Component Information > Description and Operation
Marker Lamp: Description and Operation

(20 A)
The power to these lamps is provided through the lighting control module Circuit 14 (BR) which is powered by Circuit
> Lighting and Horns > Parking Lamp > Component Information > Specifications
Parking Lamp: Specifications
Park and Turn Lamp Retaining Screws ...............................................................................................................................

> Lighting and Horns > Parking Lamp > Component Information > Specifications > Page 9909
Parking Lamp: Description and Operation

(20 A)
The power to these lamps is provided through the lighting control module Circuit 14 (BR) which is powered by Circuit
> Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis
Parking Lamp: Flow of Diagnosis
1. Verify the customer's concern by operating the parking lamps to duplicate the condition.2. Inspect to determine if

- circuitry open/shorted.
- Bulb burned out.
- Damaged connector.
(NGS)3. If inspection reveals an obvious concern that is readily serviced, correct the concern before continuing with
(DLC) (DTCs)
Data Link Connector to retrieve continuous Diagnostic Trouble Codes and to execute Self Test Diagnostics for
5. If self test is passed and no DTCs are retrieved, go to the Symptom Chart to continue diagnostics. See: Symptom
(DTC)6. If DTCs are retrieved, go to the Lighting Control Module Diagnostic Trouble Code Index to continue diagn
Code Descriptions/LCM Diagnostic Trouble Code (DTC) Index
7. If the lighting control module cannot be accessed by the NGS Tester, go to Pinpoint Test AA. See: Headlamp/Tes
Tests and General Diagnostics/Pinpoint Tests/Test AA: No Communication With Lighting Control Module
Rotunda Service Bay Diagnostic System (SBDS(R)) 418-F001 (001-00001) may also be used to diagnose this system.
> Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9912
Parking Lamp: Initial Inspection and Diagnostic Overview
1. Verify the customer's concern by operating the parking lamps to duplicate the condition.2. Inspect to determine if

- circuitry open/shorted.
- Bulb burned out.
- Damaged connector.
(NGS)3. If inspection reveals an obvious concern that is readily serviced, correct the concern before continuing with
(DLC) (DTCs)
Data Link Connector to retrieve continuous Diagnostic Trouble Codes and to execute Self Test Diagnostics for
5. If self test is passed and no DTCs are retrieved, go to the Symptom Chart to continue diagnostics. See: Symptom
(DTC)6. If DTCs are retrieved, go to the Lighting Control Module Diagnostic Trouble Code Index to continue diagn
Code Descriptions/LCM Diagnostic Trouble Code (DTC) Index
7. If the lighting control module cannot be accessed by the NGS Tester, go to Pinpoint Test AA. See: Headlamp/Tes
Tests and General Diagnostics/Pinpoint Tests/Test AA: No Communication With Lighting Control Module
Rotunda Service Bay Diagnostic System (SBDS(R)) 418-F001 (001-00001) may also be used to diagnose this system.
Parking Lamp: Diagnostic Trouble Code Descriptions




Parking Lamp: Pinpoint Tests
Test Notes
B1577-1 - B1577-3
EA1 - EA4

EB1 - EB2
EC1
EF1 - EF2
> Lighting and Horns > Parking Lamp > Component Information > Service and Repair > Front Lamp
Parking Lamp: Service and RepairFront Lamp
REMOVAL
1. Remove socket assembly from parking lamp.2. Remove two nuts retaining parking lamp to radiator grille opening
INSTALLATION
> Lighting and Horns > Parking Lamp > Component Information > Service and Repair > Front Lamp > Page 9922
Parking Lamp: Service and RepairRear Lamp
REMOVAL
1. Remove luggage compartment trim panel.2. Remove the three wing nuts that retain the rear lamp to the lower back
INSTALLATION
2 N.m (17 Lb-In)1. Follow removal procedure in reverse order.2. Tighten nuts to .
> Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations

Engine View
> Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 9927

> Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Service and Repair > Control Module
REMOVAL
INSTALLATION
> Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Service and Repair > Control Module > Page 9930
REMOVAL
INSTALLATION
> Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > Customer Interest for Exterior Ligh
Turn Signals - Intermittent Rapid Flashing
Article No.02-9-7
05/13/02
SERVICE PROCEDURE
1
3.
> Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > Customer Interest


SUPERSEDES: 01-21-3
DEALER CODING
CONDITION
BASIC PART NO. CODE
> Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > Customer Interest

13C788 42
OASIS CODES: 201000, 201100, 201200, 206000

> Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
May > 02 > Turn Signals - Intermittent Rapid Flashing
Article No.02-9-7
05/13/02
SERVICE PROCEDURE
1
3.
> Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Technical


SUPERSEDES: 01-21-3
DEALER CODING
CONDITION
BASIC PART NO. CODE
> Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Technical Service Bulletins > All Technical

13C788 42
OASIS CODES: 201000, 201100, 201200, 206000

> Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Police Option Emergency Flasher Relay #1

> Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Police Option Emergency Flasher Relay #1 > Page 9952

> Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations

Engine View
> Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 9956

> Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 9957

REMOVAL
INSTALLATION
> Lighting and Horns > Relays and Modules - Lighting and Horns > Lighting Control Module (LCM) <--> [Lamp Control Module] > Component Information > Locations

> Lighting and Horns > Relays and Modules - Lighting and Horns > Lighting Control Module (LCM) <--> [Lamp Control Module] > Component Information > Diagrams > Diagram Inform

- System Diagrams
- Grounds Diagrams
> Lighting and Horns > Relays and Modules - Lighting and Horns > Lighting Control Module (LCM) <--> [Lamp Control Module] > Component Information > Diagrams >


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:






> Lighting and Horns > Relays and Modules - Lighting and Horns > Lighting Control Module (LCM) <--> [Lamp Control Module] > Component Information > Diagrams > Page 9976
> Lighting and Horns > Relays and Modules - Lighting and Horns > Lighting Control Module (LCM) <--> [Lamp Control Module] > Component Information > Diagrams > Page 9977

REMOVAL
INSTALLATION
> Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations

> Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations > Page 9981

> Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Specifications

> Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Specifications > Page 9986
REMOVAL
INSTALLATION
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations
Transmission View

> Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 9992

> Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch (BPP) <--> [Brake Light Switch] > Component Information > Technical Service Bulletins
Position Switch (BPP): > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative
Article No.02-13-6
07/08/02
ISSUE
ACTION
Parts Block

BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch (BPP) <--> [Brake Light Switch] > Component Information > Technical
Service Bulletins > Customer Interest for Brake Pedal Position Switch (BPP): > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 10001

3.
Brake Pedal Position Switch (BPP): > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative
Article No.02-13-6
07/08/02
ISSUE
ACTION
Parts Block

BASIC PART NO. CODE
14A005 01
OASIS CODES: 201000, 201200, 203000, 203200, 503300
Service Procedure
Service Bulletins > All Technical Service Bulletins for Brake Pedal Position Switch (BPP): > 02-13-6 > Jul > 02 > Stoplamps/Shift Interlock - Inoperative > Page 10007

3.
Brake Pedal Position Switch (BPP): Description and Operation

(BPP)The Brake Pedal Position switch provides power to the stoplamps and signals various other systems, including:
- anti-lock brake control module
- shift lock actuator
- speed control servo
(15 A)
Power is provided to the BPP switch through Fuse 1 . This fuse is hot at all times. With the BPP switch closed, power i
Brake Pedal Position Switch (BPP): Service and Repair

REMOVAL
Fig. 3 Stop light switch replacement
2. Remove the hairpin retainer and slide the BPP switch, the push rod and the nylon washers and bushing away from
BPP switch by sliding the BPP switch up/down as required to remove.
Service Bulletins > Page 10010

NOTE:
Since the BPP switch side plate nearest the brake pedal is slotted, it is not necessary to remove the brake master
INSTALLATION
1. Position BPP switch so that the U-shaped side is nearest the brake pedal and directly over or under the pin. Then s
trapping the master cylinder push rod and black bushing between the stoplight switch side plates. Push BPP switc
CAUTION: Do not substitute other types of pin retainers. Replace only with a production hairpin retainer. Com
2. Assemble the wire harness connector to the BPP switch.
NOTE:
BPP switch wire harness must have sufficient length to travel with BPP switch during full stroke of brake pedal
3. Check BPP switch for proper operation.

> Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Page 10016

> Page 10017

System Diagrams
> Page 10018

Grounds Diagrams
> Page 10019

ELECTRICAL SYMBOLS
Electrical Symbols
> Page 10020

Electrical Symbols
VACUUM SYMBOLS
> Page 10021

Vacuum Symbols

BK
BL
BR
> Page 10022

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10023
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10024

> Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 10025

> Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10028

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).

Part 1 Of 3
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page
10030

Part 2 Of 3
Part 3 Of 3
Part 1 Of 2
10031

Part 2 Of 2
Part 1 Of 2
Part 2 Of 2
Flow of Diagnosis
NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
10034

-
IGNSW
Open Power(50A)
- STR/ALT (30A).
10035

Part 1 Of 3
Part 2 Of 3
Part 3 Of 3
10036

Part 1 Of 2
Part 2 Of 2
Part 1 Of 2
10037

Part 2 Of 2
10038

10039

10040

10041

Pinpoint Test G1
10042


10043


10044

10045

> Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 10046
REMOVAL
INSTALLATION
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1005
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1006

> Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10061

Theturn signal.
- hazard warning.
- cornering lamps.
- headlamp dimmer.
NORMAL OPERATION

moving thethe
the turn
FLASH-TO-PASS
NOTE:

> Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10064

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).

Part 1 Of 3
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis >
Page 10066

Part 2 Of 3
Part 3 Of 3
Part 1 Of 2
Page 10067

Part 2 Of 2

Flow of Diagnosis
NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
Page 10070

-
IGNSW
Open Power(50A)
- STR/ALT (30A).
Page 10071

Part 1 Of 3
Part 2 Of 3
Part 3 Of 3
Page 10072

Part 1 Of 2
Part 2 Of 2
Page 10073

Page 10074

Page 10075

Page 10076

Page 10077

Pinpoint Test G1
Page 10078


Page 10079


Page 10080

Page 10081

> Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 10082
REMOVAL
INSTALLATION
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page
10087

10088

System Diagrams
10089

Grounds Diagrams
10090

ELECTRICAL SYMBOLS
Electrical Symbols
10091

Electrical Symbols
VACUUM SYMBOLS
10092

Vacuum Symbols

BK
BL
BR
10093

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10094

10095

> Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10096
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 10097
-
-



REMOVAL
INSTALLATION
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation

> Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation > Page 10105

REMOVAL
INSTALLATION
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Service and Repair
REMOVAL
INSTALLATION
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Locations
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Diagram Information and Inst

- System Diagrams
- Grounds Diagrams
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Diagram


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:

> Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Page 10123

Theturn signal.
- hazard warning.
- cornering lamps.
- headlamp dimmer.
NORMAL OPERATION
TheTurn
turn the ignition
is incorporated
LANE CHANGE FEATURE
Movethe
Operate and hold
lane the turn
follows:-
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Testing and Inspection > Flow of Diagnos

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).
See: Turn Signals/Testing and Inspection/Diagnostic Trouble Code Descriptions/LCM Diagnostic Trouble Code Index

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).
Part 1 Of 3
Part 2 Of 3
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Testing and Inspection >

Part 3 Of 3

Flow of Diagnosis
NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).

NOTE: (NGS)
-Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)

- IGNSW (50A)
- STR/ALT (30A).
Part 1 Of 3

Part 2 Of 3
Part 3 Of 3


Pinpoint Test G1






Part 1 Of 2
Part 2 Of 2
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Testing and Inspection > Page 10139
REMOVAL
INSTALLATION
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Updated Rep
Article No.01-19-4
10/01/01
PARTS BLOCK

> Lighting and Horns > Trunk Lamp > Component Information > Description and Operation
Trunk Lamp: Description and Operation

The luggage compartment lamp :
- is mounted beneath package tray.
- illuminates when the luggage compartment door is opened and the battery saver feature is not active.
The luggage compartment lamp and mercury switch is located near driver side hinge on underside of luggage compartm
> Lighting and Horns > Trunk Lamp > Component Information > Service and Repair > Trunk Lamp
Trunk Lamp: Service and RepairTrunk Lamp

REMOVAL
1. Pry luggage compartment lamp away from luggage compartment rear shelf.2. Remove miniature bulb.3. Disconne
INSTALLATION
> Lighting and Horns > Trunk Lamp > Component Information > Service and Repair > Trunk Lamp > Page 10149
Trunk Lamp: Service and RepairTrunk Lamp Switch

REMOVAL
1. Release mounting tabs.2. Carefully pull switch away from luggage compartment door hinge.3. Disconnect wiring
INSTALLATION
> Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations
Turn Signal Flasher: Locations

1996 Crown Victoria shown, others similar
> Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair
Turn Signal Bulb: Service and Repair

REMOVAL
NOTE:
Make sure turn signal lamp switch is OFF.
1. Two types of bulb sockets are used for most exterior illumination:
a. Standard plastic socket.
b. Three-tab type.
2. To remove the plastic socket assembly, turn the socket counter-clockwise to the stop and remove the socket.3. Pul
INSTALLATION
1. To install, align miniature bulb and push straight into socket.2. Index the smallest tab for locating the socket and ro
> Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations

> Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations > Page 10161

> Lighting and Horns > Turn Signals > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Locations
> Lighting and Horns > Turn Signals > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Lighting and Horns > Turn Signals > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page
10167

10168

System Diagrams
10169

Grounds Diagrams
10170

ELECTRICAL SYMBOLS
Electrical Symbols
10171

Electrical Symbols
VACUUM SYMBOLS
10172

Vacuum Symbols

BK
BL
BR
10173

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Lighting and Horns > Turn Signals > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 10174
> Lighting and Horns > Turn Signals > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 10175

> Lighting and Horns > Turn Signals > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Diagrams > Page 10176

Theturn signal.
- hazard warning.
- cornering lamps.
- headlamp dimmer.
NORMAL OPERATION
TheTurn
turn the ignition
is incorporated
LANE CHANGE FEATURE
Movethe
Operate and hold
lane the turn
follows:-
> Lighting and Horns > Turn Signals > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Testing and Inspection > Flow of Diagnosis

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).
See: Testing and Inspection/Diagnostic Trouble Code Descriptions/LCM Diagnostic Trouble Code Index
> Lighting and Horns > Turn Signals > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10179

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).
Part 1 Of 3
Part 2 Of 3
> Lighting and Horns > Turn Signals > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Testing and Inspection > Flow of Diagnosis > Page
10181

Part 3 Of 3

Flow of Diagnosis
NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).

NOTE: (NGS)
-Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
10184

- IGNSW (50A)
- STR/ALT (30A).
Part 1 Of 3
10185

Part 2 Of 3
Part 3 Of 3
10186

10187

Pinpoint Test G1

10188


10189

10190

10191

Part 1 Of 2
Part 2 Of 2
> Lighting and Horns > Turn Signals > Multifunction Switch <--> [Turn Signal Switch] > Component Information > Testing and Inspection > Page 10192
REMOVAL
INSTALLATION
> Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Updated Replacement Part
Article No.01-19-4
10/01/01
PARTS BLOCK

> Lighting and Horns > Vanity Lamp > Component Information > Description and Operation
Vanity Lamp: Description and Operation

The vanity mirror lamp system consists of:
- a switch and miniature bulb assembly in each inside visor.
- circuit wiring and circuit protection.
Power is provided to the vanity mirror lamp switches through Circuit 705 (LG/O). Turning on the switch in the inside v
> Lighting and Horns > Vanity Lamp > Component Information > Description and Operation > Page 10201
Vanity Lamp: Service and Repair

NOTE: The vanity mirror is integral to the sun visor.
REMOVAL
1. Using a thin, flat-bladed screwdriver, pry vanity mirror lamp lens away from inside visor.
INSTALLATION
1. Position vanity mirror lamp lens on inside visor and snap into place.
> Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations

Engine View
> Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 10207

> Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Diagrams

> Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Diagrams > Page 10211

-
10 minutes
- (LCM)
> Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Diagrams > Page 10212
REMOVAL
INSTALLATION
> Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations

Engine View
> Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 10217

> Windows and Glass > Relays and Modules - Windows and Glass > Driver's Door Module <--> [Power Window Control Module] > Component Information > Locations > Driver's Door M

> Windows and Glass > Relays and Modules - Windows and Glass > Driver's Door Module <--> [Power Window Control Module] > Component Information > Locations > Driver's Door M

> Windows and Glass > Relays and Modules - Windows and Glass > Driver's Door Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Inform

- System Diagrams
- Grounds Diagrams
> Windows and Glass > Relays and Modules - Windows and Glass > Driver's Door Module <--> [Power Window Control Module] > Component Information > Diagrams >


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
Driver Door Module






> Windows and Glass > Relays and Modules - Windows and Glass > Driver's Door Module <--> [Power Window Control Module] > Component Information > Diagrams > Page 10238

REMOVAL
INSTALLATION
> Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams

> Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams > Page 10243

-
10 minutes
- (LCM)
> Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams > Page 10244
REMOVAL
INSTALLATION
> Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Window Switch

> Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Window Switch > Page 10249
> Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Window Switch > Page 10250
> Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > One_Touch Down

> Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > One_Touch Down > Page 10253

> Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Doors

REMOVAL
pins.
INSTALLATION
> Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Doors > Page 10256
REMOVAL
pins.
INSTALLATION
> Windows and Glass > Windows > Driver's Door Module <--> [Power Window Control Module] > Component Information > Locations > Driver's Door Module

> Windows and Glass > Windows > Driver's Door Module <--> [Power Window Control Module] > Component Information > Locations > Driver's Door Module > Page 10262

> Windows and Glass > Windows > Driver's Door Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Windows and Glass > Windows > Driver's Door Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Windows and Glass > Windows > Driver's Door Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 102
Driver Door Module



> Windows and Glass > Windows > Driver's Door Module <--> [Power Window Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 102



> Windows and Glass > Windows > Driver's Door Module <--> [Power Window Control Module] > Component Information > Diagrams > Page 10278

REMOVAL
INSTALLATION
> Windows and Glass > Windows > Power Window Motor > Component Information > Specifications > Electrical Specifications
Power Window Motor: Electrical Specifications

Window Regulator Electric Drive Current Draw
No Load.............................................................................................................................................................................
> Windows and Glass > Windows > Power Window Motor > Component Information > Specifications > Electrical Specifications > Page 10283
Power Window Motor: Mechanical Specifications
Front Door Window Channel Bracket .................................................................................................................................

> Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Front Door
Power Window Motor: Service and RepairFront Door

REMOVAL
1/4-inch
1. Remove front door trim panel and front door trim shield.2. Place window glass in full up position and secure with
access hole in door to gain access to three window regulator electric drive retaining screws.
7. Remove window regulator electric drive retaining screws using a Torx(R) Drive Bit Set 501-DS001 (D79P-2100-T
window regulator electric drive from front door power window regulator.
8. Remove window regulator electric drive from inside front door.
INSTALLATION
61. Position window regulator electric drive to front door power window regulator. Install three window regulator ele
N.m (53 Lb-In).
> Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Front Door > Page 10286

2. Position window regulator electric drive on inner panel and install three rivets.3. Connect window regulator electr
> Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Front Door > Page 10287
Power Window Motor: Service and RepairRear Door
REMOVAL
1/4-inch1. Remove rear door trim panel and watershield.2. Disconnect battery ground cable.3. Disconnect window r
5. Working through access hole, remove window regulator electric drive bracket from inner panel and slide window
gain access to three window regulator electric drive retaining screws.
6. Remove window regulator electric drive retaining screws using a Torx(R) Drive Bit Set 501-DS001 (D79P-2100-T
window regulator electric drive from rear door electric window regulator.
7. Remove window regulator electric drive from rear door.
INSTALLATION
1. Position window regulator electric drive to rear door electric window regulator and window regulator electric driv
5-7 N.m (45-61 Lb-In)window regulator electric drive screws. Tighten to .
1/4-20 x 1/2 inch 1/4-202. Position window regulator electric drive mounting bracket to inner panel. Install three riv
assemblies or equivalent metric fasteners may be used).
3. Connect window regulator electric drive harness connector.4. Connect battery ground cable.5. Remove tape from
> Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Left Rear Window Switch

> Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Left Rear Window Switch > Page 10292
> Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Left Rear Window Switch > Page 10293
> Windows and Glass > Windows > Power Window Switch > Component Information > Description and Operation > One_Touch Down

> Windows and Glass > Windows > Power Window Switch > Component Information > Description and Operation > One_Touch Down > Page 10296

> Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Front Doors

REMOVAL
pins.
INSTALLATION
> Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Front Doors > Page 10299
REMOVAL
pins.
INSTALLATION
> Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair
Back Window Glass: Service and Repair
REMOVAL
WARNING: SAFETY GLASSES AND GLOVES MUST BE WORN TO PREVENT PERSONAL INJURY.
1. Disconnect rear window defroster and antenna wires if equipped.2. Remove interior garnish mouldings and drop h
block of suitable material between headliner and roof to act as a spacer.
3. Remove panel.
> Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Page 10304

4. Use Rotunda Knife With Offset Blade 107-R1511 Rotunda interior Auto Glass Cut-Out Knife Kit 164-R2450 or e
to manufacturer's instructions when using tool.
CAUTION: Use care to avoid damage to the rear package tray cover panel.
5. Remove back window glass and moulding assemblies from vehicle using suitable suction tool. Clean area around
moistened with clean water.
1 to 1.5 mm (0.04 to 0.06 inch)6. Trim remaining urethane on pinch weld to within thickness with utility knife or ra
scratch the paint on the pinch weld. When completed, surface should be smooth and free of cuts and contaminatio
7. Check pinch weld sealing area for damaged sheet metal, rust or foreign objects which may have caused, or may ca
metal if necessary.
INSTALLATION
1. If painted sheet metal has been exposed anywhere along the flange, use the supplied wool applicator and apply ure
WSB-M2G234-C to back window glass pinch weld.
NOTE: 10 minutes A minimum of is required for primer surface to dry.
2. Install foam dam (with self-adhesive backing) around back window glass opening at end of metal flange, and at up
If moulding is already on glass, proceed to Step 4.If moulding needs to be installed, use the following procedure:
21 mm (0.8 inch)4. Clean back window glass with Ultra Clear Spray Glass Cleaner E4AZ-19C507-AA or equivalen
70 mm (2.75 inch)and wide along bottom. Wipe off glass prep and repeat prep application.
NOTE:
Wipe off Urethane Glass Prep WSB-M5B280-C2 immediately after application because it flash dries. Prep appl
6. Properly align back window glass to body.
a. Place back window glass into opening. Center it top and bottom, side-to-side. Adjust lower glass stops it neces
21 mm (0.8 inch) 70 mm (2.75 inch)7. Remove back window glass and moulding assemblies from vehicle and plac
bottom.
NOTE: five minutes Allow a minimum of for glass primer to dry.

> Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Page 10305

10. Apply an even bead of Urethane Adhesive WSB-M2G316-B around entire sheet metal pinch weld on top of existi
16 mm (0.63 inch) 8 mm (0.3 inch)should be triangular in shape, high and at base.
Leave
NOTE - a door window slightly open until adhesive is cured.
- Apply new urethane on top of existing material on pinch weld.
11. Install back window assembly onto vehicle, taking care to align marks on glass and body. This must be done befor
21C (70F)
CAUTION -
24 hours
When replacing urethane-installed glass parts, do not drive the vehicle until the urethane has cured. At and 50
- Use only urethane for service of air and water leaks in urethane-set back windows.
12. Tuck finisher strip on window moulding along the side under the ditch moulding.13. Reconnect antenna and rear w
> Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair
Front Door Window Glass: Service and Repair
Front Glass
REMOVAL
1. Remove front door trim panel and front door trim shield.2. Loosen front door glass run front retainer retaining scre
1/4-inchpunch. Using a diameter drill, drill out remainder of rivets.
CAUTION: Do not attempt to pry out the rivets as damage to the front door window glass will result.
NOTE:
Prior to removing the rivet center pins, it is necessary to place a suitable block support between the door outer p
4. Remove front door window glass.
INSTALLATION
1/4-inch 1/4-20 x 1-inch1. Insert front door window glass into front door between front door belt line outside weathe
1/4-inch 9-14 N.m (80-124 Lb-In)
assemblies and -20 nut and washer assemblies is optional). Tighten nut (if used) to . Do not exceed maximumtorq
4. Tighten front door glass run front retainer retaining screw.5. Adjust front door window glass.6. Install front door t
> Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair
Rear Door Window Glass: Service and Repair
REMOVAL
1. Remove rear door trim panel and watershield.2. Remove rear door glass run front lower retainer.
CAUTION:
Do not attempt to pry out the rivets as damage to the rear door window glass will result. Prior to removing rivet
3. Lower rear door window glass to gain access to the two rear door window channel bracket retaining rivets and rem
1/4-inchusing a drift punch. Using a diameter drill, drill out the remainder of the rivets.
> Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair > Page 10312

4. Remove rear door window glass.
INSTALLATION
1/4-inch 1/4-20 x 1 inch1. Insert rear door window glass into rear door between rear door glass outside weatherstrip
9-14 N.m (80-124 Lb-In)Tighten bolts (if used) to . Do not exceed maximum torque. Equivalent metric fasteners
4. Install rear door glass run front lower retainer.5. Adjust rear door window glass.6. Install rear door trim panel and
> Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair
Front Door Window Regulator: Service and Repair

REMOVAL
1. If front door window glass is in the down position and is inoperable, the following steps must be taken; if front do
go to Step 2.a. Remove front door trim panel and front door trim shield.b. Disconnect battery ground cable.c. Dis
CAUTION: Be careful not to strike or scratch front door window glass because it can break.
Raise front
e. Remove door regulator
window window glass to full
electric upfrom
drive position
frontbydoor
hand and secure
power windowwith tape.
regulator.f.
g. Go to Step 5.
1/4-inch2. Remove front door trim panel and front door trim shield.3. Remove front door window glass.4. Disconnec
1/4-inchfor each rivet. Using a diameter drill, drill out remainder of rivet.
6. Remove three window regulator electric drive retaining screws from inside door to remove window regulator elec
window regulator.
7. Remove two window regulator retaining nuts.8. Remove front door power window regulator from front door.
INSTALLATION
1/4-20 x 1/2 inch 1/4-201. Lubricate regulator mechanism with Teflon(R) Lubricant D2AZ-19590-A or equivalent m
equivalent metric fasteners may be used).
5. Install two upper front door power window regulator retaining nuts.6. Install window regulator electric drive with
> Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair
Rear Door Window Regulator: Service and Repair

REMOVAL
1. If rear door window glass is in the down position and is inoperable, the following steps must be taken; if rear door
to Step 2.
1/2 incha. Remove rear door trim panel and watershield.b. Mark inner door panel and drill three holes.
Be careful
CAUTION - not to drill through the mechanism behind inner door panel.
- Be careful not to strike or scratch rear door window glass because it can break.
Raise rear
c. Remove reardoor
doorwindow
electricglass to full
window up position
regulator by hand
retaining andthrough
screws secure with a clamp.
holes.d. Remove rear door electric windo
g. Go to Step 4.
CAUTION:
When servicing rear door electric window regulator assembly, regulator cable tension must not be altered. Cable
2. Remove rear door trim panel and watershield.3. Remove rear door window glass.
> Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Page 10320

1/4-inch 1/4-inch4. Disconnect window regulator electric drive harness connector.5. Remove three rivets retaining r
1/4-inch
of rear door electric window regulator to inner panel. Use drift punch to knock out center pins for each rivet. Usin
6. Remove two upper rear door electric window regulator retaining nuts.7. Remove rear door electric window regula
INSTALLATION
1. Lubricate rear door electric window regulator with Teflon(R) Lubricant D2AZ-19590-A or equivalent meeting Fo
ESB-M1C111-A.
2. Install rear bracket.
mounting door electric window regulator into access hole in inner panel.3. Position rear door electric window reg
1/4-20 x 1/2 inch 1/4-204. Install rivets retaining rear door electric window regulator to door inner panel ( bolt and n
equivalent metric fasteners may be used as alternates).
9-14 N.m (80-124 Lb-In)
5. Install two upper rear door electric window regulator retaining nuts. Tighten to .6. Install rear door electric window
> Windows and Glass > Windows > Window Track > Component Information > Service and Repair > Door Glass Run Retainer
Window Track: Service and RepairDoor Glass Run Retainer
Front
REMOVAL
1. Remove front door trim panel.2. Remove rear door window glass.3. Remove two screws retaining front door glass
front retainer and front door glass hinge side run.
INSTALLATION
9-12 N.m (80-106 Lb-In)1. Follow removal procedure in reverse order.2. Tighten screws to .
Rear
> Windows and Glass > Windows > Window Track > Component Information > Service and Repair > Door Glass Run Retainer > Page 10325

REMOVAL
1. Remove rear door window glass.2. Remove two screw and washer assemblies attaching rear door glass run front l
rear door.
INSTALLATION
9-12 N.m (80-106 Lb-In)1. Follow removal procedure in reverse order.2. Adjust rear door window glass.3. Tighten
> Windows and Glass > Windows > Window Track > Component Information > Service and Repair > Door Glass Run Retainer > Page 10326
Window Track: Service and RepairDoor Glass Top Run
REMOVAL
1. Remove front door trim panel and front door trim shield.2. Remove front door belt line inside weatherstrip.3. Rem
INSTALLATION
9-12 N.m (80-106 Lb-In)
1. Install front door glass top run into door frame.2. Push front door glass top run onto door flange starting at upper B
10. Install front door trim shield and front door trim panel.
> Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks
Windshield: Customer InterestWindshield - 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 COUGAR1995-98 MARK VIII1995-99 CONTINENTAL, GRAND MARQUIS, MY
LIGHT TRUCK: 1995-97 AEROSTAR, F SUPER DUTY1995-99 ECONOLINE, EXPLORER, F-150, F-250 HD, F-2
ISSUEThe customer may report a water leak from the windshield. This may be caused by a skip or a void in the produc
ACTIONApply a bead of Liquid Butyl Sealer (F8AZ-19554-CA) under the weatherstrip around the periphery of the wi
NOTE
DUE TO DIFFICULTY IN DETERMINING THE EXACT LOCATION OF A WATER LEAK, IT MAY BE IDEA
The following is the labor operation to be used for this repair and a chart providing Windshield Sealing Labor Times:
^ 03100B
F8AZ-19554-CA Liquid Butyl Sealer
> Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water
Leaks > Page 10335

OASIS CODES: 102000, 110000

> Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Le
Windshield: All Technical Service BulletinsWindshield - 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 COUGAR1995-98 MARK VIII1995-99 CONTINENTAL, GRAND MARQUIS, MY
LIGHT TRUCK: 1995-97 AEROSTAR, F SUPER DUTY1995-99 ECONOLINE, EXPLORER, F-150, F-250 HD, F-2
ISSUEThe customer may report a water leak from the windshield. This may be caused by a skip or a void in the produc
ACTIONApply a bead of Liquid Butyl Sealer (F8AZ-19554-CA) under the weatherstrip around the periphery of the wi
NOTE
DUE TO DIFFICULTY IN DETERMINING THE EXACT LOCATION OF A WATER LEAK, IT MAY BE IDEA
The following is the labor operation to be used for this repair and a chart providing Windshield Sealing Labor Times:
^ 03100B
F8AZ-19554-CA Liquid Butyl Sealer
> Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 99-2-3 > Feb > 99 >
Windshield - Water Leaks > Page 10341

OASIS CODES: 102000, 110000

> Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 10342
Windshield: Description and Operation

The windshield glass is standard safety glass-plastic-laminate sandwiched between two sheets of glass.
Urethane adhesive bonds the windshield glass to the window opening flange.
Windshield: Service and Repair
REMOVAL
WARNING: SAFETY GLASSES AND GLOVES MUST BE WORN TO PREVENT PERSONAL INJURY.
1. Remove windshield wiper arms and blades.2. Remove inside rear view mirror.3. Remove visors and drop headline
suitable material between headliner and roof to act as a spacer. Remove windshield side garnish moulding as requ
4. Remove cowl vent screen.5. Remove inside rear view mirror.6. Remove front door weatherstrip.

7. Use Rotunda knife With Offset Blade 107-R1511, Rotunda Interior Auto Glass Cut-Out knife kit 164-R2450 or eq
to manufacturer's instructions when using tool.
CAUTION: Use care to avoid damage to the instrument panel.
8. Remove windshield and moulding assemblies from vehicle using suitable suction tool. Clean pinch weld area arou
cloth moistened with clean water.
1 to 1.5 mm (0.04 to 0.06 inch)9. Trim remaining urethane on pinch weld to within thickness with utility knife or ra
surface should be smooth and free of cuts and contamination.
10. Check pinch weld sealing area for damaged sheet metal, rust or foreign objects which may have caused, or may ca
metal if necessary.
INSTALLATION
1. If painted sheet metal has been exposed anywhere along the flange, use the supplied wool applicator and apply Ur
WSB-M2G234-C to windshield pinch weld.
NOTE: 10 minutes A minimum of is required for primer surface to dry.
2. Install foam dam (with self-adhesive backing) around windshield glass opening at end of metal flange, and at uppe
If moulding is already on glass, proceed to Step 4.If moulding needs to be installed, use the following procedure:
21 mm (0.8 inch)4. Clean windshield with Ultra Clear Spray Glass Cleaner E4AZ-19C507-AA or equivalent meetin
70 mm (2.75 inch)and wide along bottom. Wipe off glass prep and repeat prep application.
NOTE:
Wipe off Urethane Glass Prep WSB-M5B280-C2 immediately after application because it flash dries. Prep appl
6. Properly align windshield glass to body.
a. Place windshield glass into opening. Center it top and bottom, side-to-side. Adjust lower glass stops if necessa
21 mm (0.8 inch) 70 mm (2.75 inch)7. Remove windshield glass and moulding assemblies from vehicle and place i
bottom.

NOTE: five minutes Allow a minimum of for glass primer to dry.
10. Apply an even bead of Urethane Adhesive WSB-M2G316-B around entire sheet metal pinch weld on top of the ex
16 mm (0.63 inch) 8 mm (0.3 inch)should be triangular in shape, high and at base.
Leave
NOTE - a door window slightly open until adhesive is cured.
- Apply new urethane on top of existing material on pinch weld.
11. Install windshield assembly onto vehicle, taking care to align marks on glass to marks on body. This must be done
Use only-urethane for service of air and water leaks in urethane-set windshield.
CAUTION
- 21C (70F)
24 hours
When replacing urethane-installed glass parts, do not drive the vehicle until the urethane has cured. At temper
14. Check installation for air and water leaks in urethane seal.
> Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations

> Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10351

> Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10352
REMOVAL
INSTALLATION
> Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation
-
> Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations
> Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructi

- System Diagrams
- Grounds Diagrams
> Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:

> Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 10371

Theturn signal.
- hazard warning.
- cornering lamps.
- headlamp dimmer.
OPERATION

switch, must
located be end
of the to operate
> Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).
> Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis >

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).


> Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow
of Diagnosis > Page 10377

Pinpoint Test G1




> Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 10382
REMOVAL
INSTALLATION
> Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations
> Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:
> Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10
> Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10

> Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 10397

Theturn signal.
- hazard warning.
- cornering lamps.
- headlamp dimmer.
OPERATION
-
> Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).
> Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10400

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).


> Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis >
Page 10403

Page 10404

Page 10405

Pinpoint Test G1
Page 10406


Page 10408

Page 10409

> Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 10410
Wiper Switch: Service and Repair
REMOVAL
INSTALLATION
> Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Description and Operation
Washer Fluid Level Indicator: Description and Operation

Vehicles equipped with an digital instrument cluster have a low windshield washer fluid warning indicator in the RH d
-
When the washer fluid level is approximately one-fourth full or lower, the windshield washer reservoir fluid leve
> Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation
-
> Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Front Washer Pump and Reservoir
Windshield Washer Pump: Service and RepairFront Washer Pump and Reservoir
REMOVAL
1. Remove windshield washer reservoir retaining screws and lift assembly away from front fender apron.
WARNING: WINDSHIELD WASHER FLUID CONTAINS METHANOL WHICH IS POISONOUS. OB
NOTE -
The windshield washer reservoir and cover assembly, windshield washer pump retaining ring, seal and winds
- (ACL)Engine Air Cleaner removal may aid in windshield washer reservoir removal and installation.
2. Disconnect electrical connectors and windshield washer hose.
NOTE: Windshield washer reservoir will drain with windshield washer hose disconnected.
> Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Front Washer Pump and Reservoir > Page 10421

INSTALLATION
3-5 N.m (27-44 Lb-In)1. Follow removal procedure in reverse order. Tighten screws retaining windshield washer re
Refill windshield washer reservoir and check for leaks and proper operation.
CAUTION:
Do not operate windshield washer pump until fluid is added to windshield washer reservoir. Damage to windshi
> Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Front Washer Pump and Reservoir > Page 10422
Windshield Washer Pump: Service and RepairFront Washer Pump and Seal Assembly
REMOVAL
1. Remove windshield washer reservoir. Disconnect electrical connector and windshield washer hose.2. Using a sma
INSTALLATION
1. Install seal/filter assembly.2. Lubricate inside diameter of seal with soapy solution and insert windshield washer p
seated in the seal.
3. Connect electrical connectors and windshield washer hoses and install windshield washer reservoir.
CAUTION:
4. Fill windshield washer reservoir slowly (otherwise air will be trapped in windshield washer reservoir causing it to
windshield washer pump.
5. Check for leaks and proper operation.
> Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair
Windshield Washer Reservoir: Service and Repair
REMOVAL
1. Remove windshield washer reservoir retaining screws and lift assembly away from front fender apron.
WARNING: WINDSHIELD WASHER FLUID CONTAINS METHANOL WHICH IS POISONOUS. OB
NOTE -
The windshield washer reservoir and cover assembly, windshield washer pump retaining ring, seal and winds
- (ACL)Engine Air Cleaner removal may aid in windshield washer reservoir removal and installation.
2. Disconnect electrical connectors and windshield washer hose.
NOTE: Windshield washer reservoir will drain with windshield washer hose disconnected.
INSTALLATION
> Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Page 10426

3-5 N.m (27-44 Lb-In)1. Follow removal procedure in reverse order. Tighten screws retaining windshield washer re
Refill windshield washer reservoir and check for leaks and proper operation.
CAUTION:
> Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Service and Repair
Windshield Washer Spray Nozzle: Service and Repair
REMOVAL
1. Remove windshield wiper pivot arm.2. Remove cowl vent screens.3. Remove windshield washer nozzle jet and br
INSTALLATION
> Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations
> Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10435


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:

> Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 10444

Theturn signal.
- hazard warning.
- cornering lamps.
- headlamp dimmer.
OPERATION

switch, must
located be end
of the to operate
> Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).
> Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10447

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).



Pinpoint Test G1




> Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 10455
REMOVAL
INSTALLATION
> Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments
Wiper Arm: Adjustments
The windshield wiper pivot arm and windshield wiper blade assemblies are positioned using a key and a keyway. If adj
1. Remove windshield wiper pivot arm.
> Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments > Page 10459

2. Using a small flat-end screwdriver, remove plastic key from windshield wiper pivot arm.3. Locate windshield wip
NOTE: Prior to installation of windshield wiper pivot arms, operate multi-function switch to cycle windshield w
4. Install windshield wiper pivot arm on pivot shaft and apply downward pressure on windshield wiper pivot arm. Al
windshield wiper pivot arm and slide latch using finger pressure only.
NOTE: Raise windshield wiper pivot arm slightly to allow latch to slide under windshield wiper pivot arm.
5. Lower windshield wiper pivot arm to ramp stops.

> Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments > Page 10460
Wiper Arm: Service and Repair

REMOVAL
1. Raise the windshield wiper blade end of the windshield wiper arm off of the windshield glass.
CAUTION: To prevent glass and/or paint damage, do not pry windshield wiper arm from pivot shaft with metal
2. Move the slide latch away from the windshield wiper pivot arm and slowly lower the arm onto the latch. This will
pivot arm from the pivot shaft and hold the windshield wiper blade end of the windshield wiper pivot arm off of t
3. Pull windshield wiper pivot arm off of the pivot shaft without the aid of any tools.
INSTALLATION
1. Align the keyway on the pivot shaft with the windshield wiper pivot arm.2. Push windshield wiper pivot arm onto
arm sufficiently to allow the latch to slide under windshield wiper pivot arms to the latched position using finger
4. Lower the windshield wiper blade to the windshield. If the windshield wiper blade does not touch the windshield,
in place.
> Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair
Wiper Blade: Service and Repair
REMOVAL
1. Release windshield wiper blade from windshield wiper pivot arm.2. Push windshield wiper blade away from wind
INSTALLATION
1. Align windshield wiper blade to windshield wiper pivot arm and snap into place.
> Wiper and Washer Systems > Wiper Control Module > Component Information > Locations

> Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10467

> Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10468
REMOVAL
INSTALLATION
> Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Wipers/Washers - Wiper Motor Transfer Tips
Wiper Motor: Technical Service BulletinsWipers/Washers - Wiper Motor Transfer Tips
Article No.03-7-2
04/14/03
ELECTRICAL - FRONT WIPER MOTOR - MOUNTINGBRACKET AND DEPRESSED PARK OUT ARM - TRAN
FORD:1987-1995 TAURUS1987-2002 CROWN VICTORIA
LINCOLN:1987-1997 TOWN CAR1988-1997 CONTINENTAL1993-1998 MARK VIII
MERCURY:1987-1995 SABLE1987-2002 GRAND MARQUIS
Article 02-10-1 is being republished in its entirety to update the Service Procedure.
ISSUEMotorcraft remanufactured front wiper motors do not include the mounting bracket or depressed park output arm
ACTIONThe front wiper motor mounting bracket and output arm must be removed from the old front wiper motor and
SERVICE PROCEDURE
Disassembly:
1.
Using a small flat bladed screwdriver, carefully remove the plastic output arm dust cover from the old wiper mot
NOTE
THE DUST COVER WILL BE REINSTALLED DURING ASSEMBLY.
2. Remove the output arm attaching bolt.
3.
Using a small light hammer, gently tap the backside of the output arm to remove the output arm from the wiper m
NOTE
TAKE CARE NOT TO DAMAGE THE PLASTIC WINDLATCH SLIDE OR BRACKET. IT IS NOT NECESSA
4. Remove the three (3) 8 mm wiper motor mounting bracket attaching bolts.
5. Remove the wiper motor bracket.
Assembly:
1. Position and align the old wiper motor mounting bracket onto the new wiper motor.
2. Reinstall the three wiper motor mounting bracket bolts and torque to 108-156 Lb-in. (13-17 N.m).
> Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Wipers/Washers - Wiper Motor Transfer Tips > Page 10473

3.
Verify that the plastic windlatch slide is positioned so that it can move an equal distance beyond both ends of the
4.
Apply a thin film of Silicone Brake Caliper Grease (Motorcraft Part XG-3-A) to the mating surfaces of the plastic
5. Install the output arm onto the wiper motor output shaft according to the specific application (Figure 1, views B a
> Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Wipers/Washers - Wiper Motor Transfer Tips > Page 10474

NOTE
THE OUTPUT SHAFT AND ARM ARE KEYED FOR PROPER ORIENTATION.
6. Reinstall the output arm bolt and torque to 132-180 Lb-in. (15-20 N.m).
7. Reinstall the plastic output arm dust cover.
8.
Rotate the output arm slowly clockwise one full turn by hand, then turn the output arm by hand counter-clockwis
9. Position the vehicle wiper arm linkage so that the wiper blades are at the bottom of the windshield, just above the
10.
Install the wiper motor in the vehicle and connect the wiper arm linkage per the procedures outlined in Section 01
TROUBLESHOOTING:
Parts Block

Disclaimer
> Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Page 10475
Windshield Wiper Motor

Wiper Motor: Testing and Inspection
CAUTION:
Do not handle any windshield wiper motor abusively when diagnosing wiper operations, as it will damage the magnet
1. To test the windshield wiper motor on the vehicle, disconnect the windshield wiper motor from the windshield wip
electrical connector.
2. Connect the green lead from the test equipment, such as Rotunda Alternator, Regulator, Battery and Starter Tester
battery positive (+) post.
3. Connect the positive (red) lead from the tester to the common brush terminal.4. Connect a ground first to the low-s
3.5 amps 5.5 ampsThe current draw should not exceed at low-speed and at high-speed.
Wiper Motor: Service and Repair

REMOVAL
2. Remove windshield wiper mounting arm and pivot shaft assembly.
3. Unsnap and remove windshield wiper motor and linkage cover.4. Remove retaining clip from windshield wiper m
CAUTION:
The internal permanent magnets used in the windshield wiper motor are a ceramic (glass-like) material. Care mu
INSTALLATION
8-12 N.m (71-106 Lb-In)1. Follow removal procedure in reverse order. Tighten motor retaining bolts to .
> Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > Wipers/Washers - Wiper Motor Transfer Tips
Wiper Motor Linkage: Technical Service BulletinsWipers/Washers - Wiper Motor Transfer Tips
Article No.03-7-2
04/14/03
ELECTRICAL - FRONT WIPER MOTOR - MOUNTINGBRACKET AND DEPRESSED PARK OUT ARM - TRAN
FORD:1987-1995 TAURUS1987-2002 CROWN VICTORIA
LINCOLN:1987-1997 TOWN CAR1988-1997 CONTINENTAL1993-1998 MARK VIII
MERCURY:1987-1995 SABLE1987-2002 GRAND MARQUIS
Article 02-10-1 is being republished in its entirety to update the Service Procedure.
ISSUEMotorcraft remanufactured front wiper motors do not include the mounting bracket or depressed park output arm
ACTIONThe front wiper motor mounting bracket and output arm must be removed from the old front wiper motor and
SERVICE PROCEDURE
Disassembly:
1.
Using a small flat bladed screwdriver, carefully remove the plastic output arm dust cover from the old wiper mot
NOTE
THE DUST COVER WILL BE REINSTALLED DURING ASSEMBLY.
2. Remove the output arm attaching bolt.
3.
Using a small light hammer, gently tap the backside of the output arm to remove the output arm from the wiper m
NOTE
TAKE CARE NOT TO DAMAGE THE PLASTIC WINDLATCH SLIDE OR BRACKET. IT IS NOT NECESSA
4. Remove the three (3) 8 mm wiper motor mounting bracket attaching bolts.
5. Remove the wiper motor bracket.
Assembly:
1. Position and align the old wiper motor mounting bracket onto the new wiper motor.
2. Reinstall the three wiper motor mounting bracket bolts and torque to 108-156 Lb-in. (13-17 N.m).
> Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > Wipers/Washers - Wiper Motor Transfer Tips > Page 10482

3.
Verify that the plastic windlatch slide is positioned so that it can move an equal distance beyond both ends of the
4.
Apply a thin film of Silicone Brake Caliper Grease (Motorcraft Part XG-3-A) to the mating surfaces of the plastic
5. Install the output arm onto the wiper motor output shaft according to the specific application (Figure 1, views B a
> Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > Wipers/Washers - Wiper Motor Transfer Tips > Page 10483

NOTE
THE OUTPUT SHAFT AND ARM ARE KEYED FOR PROPER ORIENTATION.
6. Reinstall the output arm bolt and torque to 132-180 Lb-in. (15-20 N.m).
7. Reinstall the plastic output arm dust cover.
8.
Rotate the output arm slowly clockwise one full turn by hand, then turn the output arm by hand counter-clockwis
9. Position the vehicle wiper arm linkage so that the wiper blades are at the bottom of the windshield, just above the
10.
Install the wiper motor in the vehicle and connect the wiper arm linkage per the procedures outlined in Section 01
TROUBLESHOOTING:
Parts Block

Disclaimer
> Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > Page 10484
Wiper Motor Linkage: Service and Repair
REMOVAL
> Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > Page 10485

2. Remove windshield wiper pivot arms.3. Remove cowl vent screens.4. Disconnect windshield washer hose from w
INSTALLATION
1. Transfer the windshield wiper motor to new mounting arm and pivot shaft assembly and follow removal procedure
10-14 N.m (88-123 Lb-In)Tighten retaining bolts to .
NOTE:
Windshield wiper mounting arms and pivot shafts are not separately replaceable, it must be replaced as an assem
> Wiper and Washer Systems > Wiper Switch > Component Information > Locations
> Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions

- System Diagrams
- Grounds Diagrams
> Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10491


System Diagrams

Grounds Diagrams

ELECTRICAL SYMBOLS
Electrical Symbols

Electrical Symbols
VACUUM SYMBOLS

Vacuum Symbols

BK
BL
BR

DG
GY
GN
LB
LG
PK
O
P
R
T
V
W
NOTE:

> Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 10500

Theturn signal.
- hazard warning.
- cornering lamps.
- headlamp dimmer.
OPERATION
-
> Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).
> Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10503

NOTE: (NGS)
Mechanical
Circuitry
-
Open4 (15A)
- 13 (15A)
- 6 (15A)
- 1 (15A)
- 5 (15A)
-
OpenIGNSW
Power(50A)
- STR/ALT (30A).





Pinpoint Test G1





Ford Crown Victoria 1998 4.6l Sfi Workshop Manual

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ford :: Ford Crown Victoria V8-281 4.

Alarm Module: LocationsPassive Anti-Theft System Module

Alarm Module: LocationsPassive Anti-Theft System Transceiver Module

Passive Anti-Theft System Control Module

Passive Anti-Theft System Transceiver Module

Alarm Module: Service and Repair

PATS Control Module

into the control module.

Driver's Door Module: Service and Repair

Door Module: Locations

Driver's Door Module: Service and Repair

Power Door Lock Control Module: Locations

The Driver's Door Module is located in center of the LH front door.

Power Door Lock Control Module: Diagram Information and Instructions

How to Find and Use These Diagrams

Diagrams are presented in three main categories:

Crown Victoria V8-281 4.6L SFI (1998)

Power Distribution Diagrams

Crown Victoria V8-281 4.6L SFI (1998)

Crown Victoria V8-281 4.6L SFI (1998)

Crown Victoria V8-281 4.6L SFI (1998)

Crown Victoria V8-281 4.6L SFI (1998)

Crown Victoria V8-281 4.6L SFI (1998)

Wire Color Code Identification

Crown Victoria V8-281 4.6L SFI (1998)

Power Door Lock Control Module: Connector Views

Driver's Door Module (C519)

Crown Victoria V8-281 4.6L SFI (1998)

Power Door Lock Control Module: Electrical Diagrams

Crown Victoria V8-281 4.6L SFI (1998)

Crown Victoria V8-281 4.6L SFI (1998)

Power Door Lock Control Module: Service and Repair

Power Mirror Control Module: Locations

The Driver's Door Module is located in center of the LH front door.

Power Mirror Control Module: Diagram Information and Instructions

How to Find and Use These Diagrams

Diagrams are presented in three main categories:

Crown Victoria V8-281 4.6L SFI (1998)

Power Distribution Diagrams

Crown Victoria V8-281 4.6L SFI (1998)

Crown Victoria V8-281 4.6L SFI (1998)

Crown Victoria V8-281 4.6L SFI (1998)

Crown Victoria V8-281 4.6L SFI (1998)

Crown Victoria V8-281 4.6L SFI (1998)

Wire Color Code Identification

Crown Victoria V8-281 4.6L SFI (1998)

Power Mirror Control Module: Connector Views

Driver's Door Module (C519)

Crown Victoria V8-281 4.6L SFI (1998)

Power Mirror Control Module: Electrical Diagrams

Crown Victoria V8-281 4.6L SFI (1998)

Crown Victoria V8-281 4.6L SFI (1998)

Power Seat Control Module: LocationsDriver's Door Module

The Driver's Door Module is located in center of the LH front door.

Power Seat Control Module: LocationsDriver's Seat Module

The Driver's Seat Module is located below the driver's seat.

Power Seat Control Module: Diagram Information and Instructions

How to Find and Use These Diagrams

Diagrams are presented in three main categories:

Crown Victoria V8-281 4.6L SFI (1998)

Power Distribution Diagrams

Crown Victoria V8-281 4.6L SFI (1998)

Crown Victoria V8-281 4.6L SFI (1998)

Crown Victoria V8-281 4.6L SFI (1998)