Keith Browning

It went to a Ford dealer in JERSEY CITY /forums/images/%%GRAEMLIN_URL%%/wink.gif and the zone manager/Rep wanted us to call him if the owner pulled the truck out of our dealer.

If this engine has a history of multiple injector problems in the same cylinder you need to inspect and replace the hold down clamp but more importantly the injector cup. Once an injector loosens to the extent that the copper gasket is pounded away the cup is beat up as well and cannot provide a good sealing surface. #8 too! Whoo Whee! That sucks in chassis but it can be done.

Now I will NEVER know what happened! They towed the truck out of here today. I am so sad! /forums/images/%%GRAEMLIN_URL%%/laugh.gif I do want to know happened though. I still have my oil samples and I just ordered the NAPA test kit... what the heck!

This is what Ford had to say in response to my Hot-Line contact:

I knew the day would come that I would run into this. An '06 350 with a 6.0L was dragged in for running rough. Wouldn't start for me. Long story short it had no fuel pressure due to a bad pump. Filters were not bad but I did see fine metal debris in the secondary, I also noticed my fuel sample was clear and didn't smell right. It was easy to put 2 & 2 together, this was an Aviation Enterprises service truck. The guy services aircraft tow vehicles and fuel trucks... with an 06 Harley Davidson F350. /forums/images/%%GRAEMLIN_URL%%/rolleyes.gif He had two containers of Jet fuel in the bed which I sampled and matched it to the sample I took from the HFCM. HE approved the repair, truck runs well actually but I am afraid he could have damaged other things or caused other long term affects. If he doesn't want the old parts I will open the pump up and see if there was actually damage that looks like a lubricity issue. After I was done I contacted the Hot Line just to see what they would say. Oh boy. Hi guys! Any way I now have a sample of Jet Fuel.

I had a bullshit reply all typed up about the FQR engine in my shop that has made noise and missed from the first second it was started. As I read my statement I started to feel like just another monkey trying to fuck the same old football as the rest of the monkeys ...but sometimes I digress. Regardless of whom is responsible for a failure, we must examine the part, component, system or whatever "it" is that has broken and make a determination as to what went wrong and why. THEN and only then we can determine who's responsibility the repair is, be it the customer's, Ford's, or God forbid, our own. /forums/images/%%GRAEMLIN_URL%%/surprise.gif I believe Ford is pulling a lot of crap right now but this process is not new to us. It would be too easy for us to assume the engine is defective as in my example, but I would be horrified to send the engine back only to be charged back because somebody left a rag in the intake, forgot to clean out the intake... or... or... ...never changed the OTA cooler, or didn't flush the OTO cooler and lines or flow tested the cooing system... or... or... I hope you see where I am going with this. I would bet my mortgage that more often than not repeat failures have historically been created at the "hands of the technicians" rather than by the manufacturers. Like Jim stated, shit happens, sometimes we have to suck it up. /forums/images/%%GRAEMLIN_URL%%/puke.gif I doubt it makes it feel any better Blake but we have all been there and I feel your pain.

I find the idea of the joint venture encouraging in a time when the industry is suffering badly. Development of new technologies benefits everyone involved right down to the consumer and raises the bar for the development of new technologies. As a country we definitely need to accelerate our efforts in new powertrains, fuels and rethink transportation in general. I hope that Ford and GM follow through with this and I definately would not consider this "the end."

2008 Truck & Diesel SSMs 1802 - 2008 - 2009 5R110W COLD WEATHER TRANSMISSION FAILURE IN VEHICLES BUILT BETWEEN 5/18/2007 AND 11/1/2008 SEE TSB 08-26-04 FOR DETAIL 08-26-04 1801 - DRIVEABILITY - NO START, HARD START, RUNS ROUGH - FUEL INJECTION CONTROL MODULE DIAGNOSIS - 6.0L DIESEL SEE TSB 08-26-03 FOR DETAIL 08-26-03 1800 - VEHICLES EQUIPPED WITH THE TIRE PRESSURE MONITORING SYSTEM SWAPPING WHEELS ON 2009 VEHICLES WITHOUT RETRAINING THE TIRE PRESSURE MONITORING SYSTEM (TPMS) SENSORS TO THE VEHICLE MODULE WILL SET A TPMS FAULT. REFER TO TPMS SENSOR TRAINING IN SECTION 204-02 WHEELS AND TIRES IN THE SERVICE MANUAL OR REFER TO THE SERVICE TIP TPMS SENSOR TRAINING ON THE PTS WEBSITE. 1797 - 2008 F-SUPER DUTY GASOLINE ENGINES WITH DTC P0111 SOME 2008 MODEL YEAR F250-550 SUPER-DUTIES EQUIPPED WITH 5.4L 3-VALVE OR 6.8L-3V ENGINES MAY EXHIBIT MIL AND DIAGNOSTIC TROUBLE CODE(DTC) P0111 INTAKE AIR TEMPERATURE(IAT) SENSOR 1 CIRCUIT RANGE/PERFORMANCE DURING COLD AMBIENT TEMPERATURES WITH UTILIZATION OF A BLOCK HEATER. IF NORMAL PCED DIAGNOSTIC PROCEDURES DO NOT RESOLVE VEHICLE CONCERN DO NOT ATTEMPT FURTHER REPAIRS. CONFIRM WITH CUSTOMER THAT THIS CONDITION ONLY OCCURS WHEN THE ENGINE BLOCK HEATER IS USED AS REPLACEMENT OF SENSORS AND COMPONENTS WILL NOT RESOLVE. ENGINEERING IS CURRENTLY INVESTIGATING. MONITOR OASIS FOR UPDATES. 1795 - 2009 F-SUPER DUTY 6.4L DRW AND 6.8L DRW - 2" HITCH ADAPTER AND PIN NO LONGER INCLUDED WITH 15K BUILT FORD TOUGH TRAILER HITCH RECEIVER IN PRODUCTION 2009 F-SUPER DUTY VEHICLES EQUIPPED WITH 6.4L DUAL REAR WHEELS (DRW) OR 6.8L DRW NO LONGER INCLUDES THE 2" HITCH ADAPTER AND PIN FOR THE 2 1/2" OR 15K BUILT FORD TOUGH TRAILER HITCH RECEIVER. DO NOT INSTALL THE 2" HITCH ADAPTER (P/N 5C3Z 19H282 AB) OR PIN KIT (P/N 5C3Z 19A326 A), AS THIS IS NO LONGER A PART OF THE TRAILER HITCH PACKAGE AND IS A NON-WARRANTABLE ITEM. THE 2" HITCH ADAPTER AND PIN KIT ARE STILL AVAILABLE TO THE CUSTOMER THROUGH FORD PARTS AND SERVICES. 1790 - 2008-2009 F-SUPER DUTY 650/750 - CATERPILLAR - SERVICE ENGINE SOON LAMP FLASHING REGENERATION (DPF) - BUILT ON OR BEFORE 6/26/2008 SEE TSB 08-26-01 FOR DETAIL 08-26-01 1788 - IDS REQUIREMENTS FOR SYNC 911 ASSIST AND VEHICLE HEALTH REPORT (VHR) SERVICE TIP - VEHICLES EQUIPPED WITH SYNC 911 ASSIST™ AND VEHICLE HEALTH REPORT (VHR) SERVICES OR THAT HAVE BEEN UPGRADED TO ACTIVATE THESE SERVICES, WILL REQUIRE IDS/PDS VERSION B58 OR HIGHER TO PROPERLY DIAGNOSE OR COMMUNICATE WITH THE SYNC (APIM) MODULE. IF IDS/PDS VERSION B58 OR HIGHER IS NOT INSTALLED IDS/PDS WILL FAIL TO COMMUNICATE WITH THE SYNC (APIM) MODULE. IDS/PDS VERSION B58 SHOULD BE AVAILABLE IN DEALERS BY 12/1/08. 1787 - 2009 F-SUPER DUTY 650/750 -REVISED BLEED PROCEDURE MERITOR WABCO SYSTEM - BRAKE WARNING LIGHT AND/OR ABS LIGHT ON DTCS - SID 57 FMI 10 AND/OR SID 60 FMI 10 SEE TSB 08-25-11 FOR DETAIL 08-25-11 1783 - 2009 F-SUPER DUTY - 6.4L - VEHICLES BUILT PRIOR TO 12/1/2008 - DIESEL CALIBRATION UPDATES SEE TSB 08-25-10 FOR DETAIL 08-25-10 1782 - 2008 F-SUPER DUTY - 6.4L - VEHICLES BUILT BETWEEN 1/3/2008 AND 9/15/2008- DIAGNOSTIC TROUBLE CODES P0128, P0196, P1335, P0404, P0406, P246C AND P2463 SEE TSB 08-25-09 FOR DETAIL 08-25-09 1781 - 2008 F-SUPER DUTY - 6.4L - VEHICLES BUILT BETWEEN 8/3/2007 AND 1/2/2008 - MODULE REPROGRAMMING SEE TSB 08-25-08 FOR DETAIL 08-25-08 1780 - 2008 F-SUPER DUTY - 6.4L - VEHICLES BUILT PRIOR TO 8/2/2007 - MODULE REPROGRAMMING SEE TSB 08-25-07 FOR DETAIL 08-25-07 1743 - 2008-2009 F-SUPER DUTY 250-550 - 6.4L DIESEL - WHITE SMOKE IN DAMP WEATHER CONDITIONS WHEN ACCELERATING - VEHICLES BUILT BEFORE 10/1/2008 SEE TSB 08-25-01 FOR DETAIL 08-25-01 1742 - 2004-2008 MULTIPLE VEHICLES - CIGAR LIGHTER / POWER POINT FUSE REPLACEMENTS CUSTOMERS SHOULD BE ADVISED THAT ANY AFTER MARKET DEVICE PLUGGED INTO THE CIGAR LIGHTER / POWER POINT THAT CREATES AN OVER CURRENT CONDITION EXCEEDING THE 12VDC (180W/20A) RATING AND CAUSING THE 20A FUSE TO BLOW, IS NOT COVERED UNDER THE VEHICLE WARRANTY. POWER POINT / CIGAR LIGHTER SOCKETS HAVE A LOAD CAPACITY NOT TO EXCEED 12VDC/180W (20AMP). REPAIRS ARE NOT REIMBURSABLE UNDER WARRANTY IF 1) CUSTOMER USE OF THE POWER POINT(S) / CIGAR LIGHTER EXCEEDS THE 12VDC/180W (20AMP) RATING OF THE CIRCUIT AND CAUSES THE FUSE TO BLOW AS DESIGNED. 2) ALTERATION OR MODIFICATION OF THE VEHICLES ELECTRICAL SYSTEM AFTER THE VEHICLE LEAVES FORDS CONTROL. FUSE REPLACEMENT DUE TO OVERLOADING OF THE CIRCUIT BY THE CUSTOMER IS NOT A WARRANTABLE REPAIR. 1741 - CATERPILLAR - LOWER RADIATOR HOSE CHAFFE SEE TSB 08-24-11 FOR DETAIL 08-24-11 1735 - 2005-2009 EXPEDITION/NAVIGATOR, 2005-2008 F-150, F250-F550 AND 2006-2008 MARK LT - WATER LEAKS AT ROOF OPENING PANEL DURING HIGH PRESSURE CAR WASH SEE TSB 08-24-08 FOR DETAIL 08-24-08 1731 - 2008 - 2009 F-SUPER DUTY - 6.4L DIESEL COOLANT FILL 6.4L DI WITH TWO VENT PORT DEGAS BOTTLE COOLANT FILL (WSM RADKITPLUS PROCEDURE RECOMMENDED). WSM FILL AND BLEED WITHOUT RADKITPLUS PROCEDURE BEING UPDATED TO: 1)WITH ENGINE OFF, FILL DEGAS BOTTLE TO BOTTOM OF FILLER NECK. 2)START ENGINE AND IDLE FOR 2 MINUTES. 3)REFILL TO THE BOTTOM OF FILLER NECK. 4)RUN ENGINE AT 2000 RPM FOR 5 MINUTES. 5)REFILL TO BOTTOM OF FILLER NECK. 6)INSTALL DEGAS BOTTLE CAP. NOTE, DRIVING VEHICLE FOR APPROX 5 MILES SHOULD DROP COOLANT TO PROPER LEVEL IN DEGAS BOTTLE. WSM COOLANT LEVEL CHECK BEING UPDATED TO:1)COOL ENGINE COOLANT LEVEL SHOULD BE WITHIN COLD FILL RANGE OF DEGAS BOTTLE. 2)WARMED ENGINE AS INDICATED BY THE TEMPERATURE GAUGE READING IN MIDDLE OF NORMAL RANGE, COOLANT LEVEL SHOULD BE 10-20MM ABOVE TOP OF COLD FILL RANGE IF DEGAS CAP IS INSTALLED AND 20 30MM ABOVE TOP OF COLD FILL RANGE IF DEGAS CAP IS REMOVED. 1728 - 2007-2009 MODEL YEAR GAS ENGINE VEHICLES - HIGHER THAN NORMAL IDLE SPEEDS SOME 2007-2009 MODEL YEAR VEHICLES EQUIPPED WITH A GAS ENGINE, WITH LESS THAN 50 TOTAL STARTS, OR LESS THAN 5 CONTINUOUS MILES OF DRIVING BETWEEN STARTS, MAY EXHIBIT HIGHER THAN NORMAL ENGINE IDLE SPEEDS. PLEASE INFORM THE CUSTOMER THIS IS A NORMAL CHARACTERISTIC. SERVICE SHOULD NOT ATTEMPT REPAIR. AFTER 5 CONSECUTIVE MILES OR 50 STARTS, THE IDLE SHOULD RETURN TO NORMAL. 1724 - 2008-2009 F-SUPER DUTY 250/350 SINGLE REAR WHEEL (SRW) - SHUDDER/VIBRATION ON ACCELERATION (ESPECIALLY WHEN LOADED) SEE TSB 08-24-06 FOR DETAIL 08-24-06 1720 - 1999-2009 MULTIPLE VEHICLES - FLUTTER/TURBULENCE NOISE AT HIGHWAY SPEEDS WITH REAR WINDOWS OR MOON/SUN ROOF OPEN SOME 1999-2009 VEHICLES MAY EXHIBIT A FLUTTER/TURBULENCE NOISE (HELICOPTER NOISE) AT HIGHWAY SPEEDS WHEN THE REAR DOOR WINDOW(S) OR SUN/MOON ROOF ARE OPEN. THIS CONDITION IS A CHARACTERISTIC OF THE VEHICLE BODY DESIGN AND IS ALSO A CHARACTERISTIC OF COMPETITIVE VEHICLES WITH A SIMILAR BODY STYLE. THIS CONDITION CAN BE REDUCED BY LOWERING EITHER ONE, OR BOTH, OF THE FRONT WINDOWS AT LEAST 2 INCHES. NO SERVICE ACTION IS RECOMMENDED FOR THIS CONDITION. 1715 - DIAGNOSTICS FOR A VEHICLE THAT HAS NO START/NO COMMUNICATION WITH THE PCM WHEN PERFORMING DIAGNOSTICS FOR A VEHICLE THAT HAS NO START/NO COMMUNICATION WITH THE PCM, IDS MAY DISPLAY THE MESSAGE 'THE PCM IS BLANK'. PRIOR TO PCM REPLACEMENT, VISUALLY INSPECT FUSES FOR THE PCM. BACK FEED THROUGH THE PCM CAN ILLUMINATE A TEST LIGHT ON BOTH SIDES OF AN OPEN FUSE. VALIDATE POWERS AND GROUNDS TO THE PCM LOAD TESTED AND VOLTAGE DROPPED. REFER TO PC/ED PINPOINT TEST QA1, UNABLE TO ACTIVATE SELF-TEST/NETWORK COMMUNICATION ERROR, FOR ADDITIONAL DIAGNOSTICS. 1686 - ANNOUNCING TWO NEW DIESEL COOLANT FLUSH PROCEDURES THERE ARE NOW TWO NEW DIESEL COOLING SYSTEM FLUSH PROCEDURES. TSB 08-23-1, TO BE USED IF THE COOLING SYSTEM IS CONTAMINATED (WITH OIL, FUEL OR TRANS. FLUID) AND A NEW UNIQUE DIESEL COOLING SYSTEM FLUSH PROCEDURE LOCATED IN THE ONLINE WSM, SECTION 303-03. THE FINAL STEPS IN BOTH PROCEDURES REQUIRE THE USE OF MOTORCRAFT ENGINE COOLING SYSTEM IRON CLEANER (VC-9), TO ENSURE THAT THE COOLING SYSTEM IS FREE OF RUST. ALL STEPS MUST BE COMPLETED IN ORDER TO PROPERLY CLEAN THE COOLING THE COOLING SYSTEM. ANY DEVIATION FROM THESE SERVICE PROCEDURES WILL RESULT IN SHORTENED COOLANT PROTECTION AGAINST CORROSION IN THE COOLING SYSTEM. 1665 - 2008 - 2009 F-SUPER DUTY - 6.4L DIESEL ENGINE OIL LEVEL DIAGNOSTIC AID ON 6.4L ENGINES, TO PREVENT SERIOUS ENGINE DAMAGE IT IS CRITICAL TO ACCURATELY MEASURE ENGINE OIL LEVELS DURING VEHICLE DIAGNOSTICS. TO PROPERLY DETERMINE ENGINE OIL LEVEL, THE ENGINE MUST BE AT NORMAL OPERATING TEMPERATURE, VEHICLE IS PARKED ON A LEVEL SURFACE AND ENGINE OFF FOR 10 MINUTES TO ENSURE ALL ENGINE OIL HAS RETURNED TO OIL PAN. USE THE SHORT STICK METHOD DESCRIBED IN PCED HARD START/NO START DIAGNOSTIC SUBROUTINES-SECTION 4. IF OIL IS OVERFULL, CHECK THE CHARGE AIR COOLER (CAC) FOR LIQUID CONTAMINATION. SOME RESIDUAL OIL IN THE CAC SYSTEM IS A NORMAL CHARACTERISTIC. IF THE CAC HAS EXCESSIVE OIL, ANY FUEL OR METAL CONTAMINATION, A THOROUGH CLEANING OF THE CAC SYSTEM IS NECESSARY. REFER TO WORKSHOP MANUAL SECTION 303-12 FOR CLEANING PROCEDURES AND PCED PINPOINT TESTS AND SYMPTOM CHARTS TO DIAGNOSE ROOT CAUSE OF OIL OVERFILL. 1664 - 2008 F-350/450/550 DUAL REAR WHEEL (DRW) REAR FENDER SIDE MARKER LAMPS LOOSE SEE TSB 08-23-10 FOR DETAIL 08-23-10 1647 - 1992-2008 MUSTANG/E-SERIES/F150/F-SUPER DUTY - AUTOMATIC TRANSMISSION INSTALLATION TIP TO PREVENT REPEAT AUTOMATIC TRANSMISSION FAILURES, CHECK FOR AND REPLACE ANY MISSING DOWEL PINS BEFORE INSTALLING THE TRANSMISSION. THE ORIGINAL DOWEL PINS ON THE ENGINE MAY HAVE COME OUT DURING THE INITIAL REPAIR OR REMOVAL OF THE TRANSMISSION. FAILURE TO HAVE BOTH DOWEL PINS INSTALLED CAN CAUSE A MISALIGNMENT BETWEEN THE CONVERTER AND THE PUMP. THIS MISALIGNMENT CAN LEAD TO TRANSMISSION FAILURE. 1643 - 6.0L DIESEL FUEL IN ENGINE COOLANT DIAGNOSTICS SEE TSB 08-23-08 FOR DETAIL 08-23-08 1577 - MODULE PREPROGRAMMING CONCERNS/ERRORS MAY BE CAUSED BY THE FOLLOWING: DATA LINK CONNECTOR (DLC) OR VEHICLE COMMUNICATION MODULE (VCM) BECOMING DISCONNECTED, LOW VOLTAGE ON THE IDS LAP TOP OR THE VEHICLE'S BATTERY, ALLOWING THE IDS TO ENTER ANY TYPE OF SLEEP MODE. IF THERE IS AN INTERRUPTION DURING REPROGRAMMING, DO NOT DELETE THE SESSION. MODULE RECOVERY IS ONLY POSSIBLE IF THE ORIGINAL SESSION IS USED| IF THE ORIGINAL SESSION HAS BEEN DELETED, THE ONLY WAY TO CORRECT THE CONCERN IS TO PURCHASE A NEW MODULE WHICH WILL NOT BE COVERED UNDER WARRANTY. 1574 - 2008-2009 SUPER-DUTY F250-550 6.4L DIESEL DIAGNOSTIC TROUBLE CODE U0073 SOME 2008-2009 F250-550 SUPER-DUTIES EQUIPPED WITH 6.4L DIESEL ENGINES MAY EXHIBIT AN INTERMITTENT NO CRANK CONCERN WITH DIAGNOSTIC TROUBLE CODE(DTC) U0073- CONTROL MODULE COMMUNICATION BUS A OFF. NETWORK DTCS ARE OFTEN A RESULT OF INTERMITTENT CONCERNS SUCH AS FAULTY WIRING, LOW BATTERY VOLTAGE OR MODULE REPROGRAMMING. REPLACING A MODULE TO RESOLVE A NETWORK DTC IS UNLIKELY TO RESOLVE THE CONCERN. CHECK FOR WIRE CHAFES OR PINCHED WIRES AND PERFORM A WIGGLE TEST ON CONNECTORS FOR THE FOLLOWING MODULES: RESTRAINT CONTROL, TRAILER BRAKE CONTROLLER. INSTALLATION OF AFTERMARKET THROTTLE CONTROLLERS AND BODY-BUILDER MODIFICATIONS MAY HAVE DAMAGED THE CAN NETWORK OR WIRING. CONFIRM THAT NO VEHICLE MODIFICATIONS HAVE BEEN TIED INTO THE CAN NETWORK. REFERENCE WORKSHOP MANUAL SECTION 418-00-1 FOR OTHER DTC DIAGNOSTIC ROUTINES. 1573 - 2009 F-SUPER DUTY - TRAILER TOW WIRING NOT INCLUDED AS STATED ON LOOSE ITEMS CHECKLIST ON SOME 2009 F-SUPER DUTY VEHICLES THE LOOSE ITEMS CHECKLIST STATES INCORRECTLY THAT A TRAILER TOW WIRING KIT IS INCLUDED WITH THE VEHICLE. THE ONLY VEHICLES WHICH WILL RECEIVE THIS KIT ARE CHASSIS CAB (NARROW FRAME) TRUCKS THAT ARE NOT EQUIPPED WITH A TRAILER BRAKE CONTROLLER (TBC). ENGINEERING IS CURRENTLY IN THE PROCESS OF CORRECTING THE LOOSE ITEMS CHECKLIST, CONTINUE TO MONITOR OASIS. 1572 - 2008 F-SUPER-DUTY 6.4L DIESEL - WHITE SMOKE DURING REGENERATION AT AMBIENT TEMPERATURES BELOW APPROXIMATELY 55 F(13 C) 2008 F-SUPER DUTY F250-550 EQUIPPED WITH 6.4L DIESEL ENGINES THAT EXHIBIT WHITE SMOKE DURING DIESEL PARTICULATE FILTER REGENERATION AT AMBIENT TEMPERATURES BELOW APPROXIMATELY 55 F(13 C). REPROGRAM THE APPROPRIATE VEHICLE MODULES PER FIELD SERVICE ACTION 08B07 BEFORE PERFORMING DIAGNOSTICS AND CLEARING ALL DIAGNOSTIC TROUBLE CODES(DTCS) FROM ALL MODULES. IF DTC'S ARE GENERATED AFTER REPROGRAMMING AND DTC CLEARING, FOLLOW NORMAL DIAGNOSTIC SERVICE PROCEDURES TO ADDRESS THESE DTC'S OR SYMPTOMS. 1571 - SOME VEHICLES MAY EXPERIENCE PROGRAMMING DIFFICULTIES RESULTING IN CORRUPT MODULE DATA OR BLANKED MODULES. HARDWIRE CONNECTIONS ONLY ARE RECOMMENDED DURING THE PROGRAMMING/REPROGRAMMING PROCESS. PAST REPORT INFORMATION INDICATES CONCERNS WITH WIRELESS IDS AS ROOT CAUSE. IN THE EVENT A MODULE BECOMES CORRUPT/BLANKED, ATTEMPT RECOVERY WITH A BATTERY CHARGER INSTALLED ON THE VEHICLE, IDS ON A WALL CHARGER, AND THE IDS PROGRAMMING CABLE TO THE VEHICLES DATA LINK CONNECTOR. IF THE MODULE CANNOT BE RECOVERED, MODULE REPLACEMENT MAY BE REQUIRED. 1568 - ANNOUNCING FIELD SERVICE ACTION 08B07 CUSTOMER SATISFACTION PROGRAM 08B07: CERTAIN 2008 MODEL YEAR F-SUPER DUTY VEHICLES EQUIPPED WITH A 6.4L DIESEL ENGINE REPROGRAM THE POWERTRAIN CONTROL MODULE (PCM) AND INSTRUMENT CLUSTER (IC). THIS HAS BEEN POSTED TO FMCDEALER.COM 1567 - ANNOUNCING FIELD SERVICE ACTION 08B06 CUSTOMER SATISFACTION PROGRAM 08B06: CERTAIN 2008 MODEL YEAR F-SUPER DUTY VEHICLES EQUIPPED WITH A 6.4L DIESEL ENGINE COOLING SYSTEM VENTURI TEE INSTALLATION. THIS HAS BEEN POSTED TO FMCDEALER.COM 1536 - 2008- 2009 SUPER-DUTY F250-550 - 6.4L DIESEL - U-CODE NETWORK TEST SOME 2008-2009 SUPER-DUTY F250-550 EQUIPPED WITH A 6.4L DIESEL MAY HAVE CODES U0073, U0100, U0121, P1000, U0074, U0101, U0115, U0164, OR ALL CMDTCS WHEN FIRST PERFORMING A NETWORK TEST AFTER IDS HAS ESTABLISHED A NEW SESSION. THESE CODES CAN BE EXPECTED AND SHOULD BE ABLE TO BE CLEARED. IF YOU CLEAR THESE CODES AND ANY OF THEM RETURN THEN INSPECT FOR A HARD FAULT LOSS OF COMMUNICATION. THE CODES ARE CAUSED BY A STRATEGY WHEN THE PCM AND THE IDS INTERACT WHILE ESTABLISHING COMMUNICATION. IF THESE CODES DO NOT RETURN AFTER CLEARING NO REPAIR RECOMMENDED. 1535 - 2008-2009 F-SUPER DUTY 6.4L - WIRE CHAFE/15-WAY CONNECTOR DIAGNOSTICS SOME 2008 F-SUPER DUTY 6.4L MAY EXHIBIT INTERMITTENT INJECTOR CIRCUIT OPEN DTC'S AND OR MISFIRE/ROUGH RUNNING AND/OR LACK OF POWER CONDITION. CHECK FOR POTENTIAL WIRE CHAFE AT DRIVER'S SIDE INJECTOR WIRE HARNESS CONTACTING BANJO FITTING ON THE FUEL FILTER HOUSING. VERIFY THE 15-WAY CONNECTOR TO ROCKER CARRIER IS FULLY SEATED. IF CONCERN REMAINS, REMOVE VALVE COVER FOR EFFECTED CYLINDER INJECTOR AND VERIFY THE ELECTRICAL CONNECTOR LOCKING TABS ARE FULLY SEATED ON ALL THE OTHER INJECTORS ON THAT BANK ARE FULLY SEATED. REMOVE ONLY ROCKER COVER(S) FOR INJECTORS INDICATED BY DTCS. IF SUSPECT CONNECTOR IS FULLY SEATED CONTINUE W/ NORMAL DIAGNOSTICS. NOTE: SOME UNDER VALVE COVER 15-WAY CONNECTIONS WERE SECURED BY AN O-RING. TO DISCONNECT THE O-RING MUST BE CUT. WHEN RECONNECTING THE CONNECTOR USE A 6" ZIP-TIE TO ENSURE THE CONNECTOR STAYS. 1486 - 2006-2009 F-SUPER DUTY - 4WD HUB USEAGE - SERVICE TIP THE OPTIMUM 4 WHEEL DRIVE FRONT HUB USEAGE FOR 2006-2009 F-SUPER DUTY VEHICLES, ADVISE CUSTOMERS OF THE FOLLOWING: 4WD USEAGE IS NOT RECOMMENDED ON DRY PAVEMENT. ON MANUAL SHIFT ON STOP (MSOS) 4X4 SYSTEMS IN 2WD MODE, ROTATE BOTH HUB LOCKS TO THE "FREE" POSITION. ON ELECTRONIC SHIFT ON THE FLY (ESOF) 4X4 SYSTEMS IN 2WD MODE, ROTATE BOTH HUB LOCKS TO THE "AUTO" POSITION. IT IS NOT RECOMMENDED TO OPERATE MSOS AND ESOF 4X4 SYSTEMS WITH THE HUB LOCKS IN THE "LOCK" POSITION. FOLLOWING THESE RECOMMENDATIONS WILL ENABLE PROPER DISENGAGEMENT OF THE TRANSFER CASE, DECREASE TIRE WEAR, IMPROVE FUEL ECONOMY AND MAY ALSO IMPROVE THE VEHICLES NOISE, VIBRATION AND HARSHNESS (NVH) CHARACTERISTICS BY REDUCING THE NUMBER OF MOVING COMPONENTS WHEN OPERATING IN 2WD MODE. REFER TO THE VEHICLES OWNER GUIDE FOR ADDITIONAL DETAILS. 1466 - 2003-2008 MULTIPLE VEHICLES - MISFIRE, LACK OF POWER, BUCK/JERK, EXCESSIVE SMOKE, CRANK/NO START - 6.0L ENGINE - DIAGNOSTICS FOR FUEL SYSTEM - SERVICE TIPS SEE TSB 08-20-01 FOR DETAIL 1465 - 6.0L EGR VALVE DIAGNOSTICS INVESTIGATION SOME 6.0L EQUIPPED VEHICLES MAY EXHIBIT DTC P0401, P0402, P0404, P1335 AND P1408 ALONE OR IN COMBINATION. DURING DIAGNOSTICS, PINPOINT TESTING MAY LEAD TO EGR VALVE REPLACEMENT. SOME NEW 6.0L EGR VALVES ARE FAILING THE EGRVP RESPONSE TEST (EGRDC VS. EGRVP) DURING THE IDS EGR AIR MANAGEMENT TESTING PROCEDURES. WHEN PERFORMING THE IDS EGR TEST, THE VALVES POSITION, ON OPENING, CAN CROSS THE LIMITS ON THE GRAPH TURNING IT RED AND FAILING THE TEST. ENGINEERING IS AWARE OF THE ISSUE AND IS INVESTIGATING. IF NO DRIVABILITY ISSUES ARE PRESENT, DO NOT REPLACE THE VALVE. IF DRIVABILITY ISSUES ARE PRESENT, PERFORM THE PERFORMANCE DIAGNOSTIC SHEET SKIPPING THE EGR PORTION. FOR OTHER DTC'S, FOLLOW THE APPROPRIATE PINPOINT TEST. 1464 - 2004-2008 E-SERIES/2003-2007 F-SUPER DUTY/2003-2005 EXCURSION/2006-2009 LOW CAB FORWARD/2004-2007 F650-F750 - OIL COOLER SERVICE TIP SOME 6.0L AND 4.5L DIESEL EQUIPPED VEHICLES MAY EXPERIENCE VARIOUS DRIVEABILITY SYMPTOMS AFTER OIL COOLER SERVICE. THIS MAY BE THE RESULT OF THE IPR BECOMING CONTAMINATED AND BEING UNABLE TO CONTROL ICP PROPERLY. IT IS STRONGLY RECOMMENDED TO COMPLETELY CLEAN OFF ALL OIL AND DEBRIS PRIOR TO OIL COOLER COVER REMOVAL AND TO INSPECT THE OIL PUMP INLET STRAINER SCREEN FOR DAMAGE PRIOR TO OIL COOLER REPLACEMENT. IF THE SCREEN IS DAMAGED, IT MUST BE REPLACED. THE RESERVOIR MUST BE COMPLETELY CLEANED TO ENSURE THERE IS NO CONTAMINATION TO THE HIGH PRESSURE OIL SYSTEM FROM DEBRIS ENTERING THE OIL DURING OIL COOLER REPLACEMENT. AFTER CLEANING, PRE-FILLING THE RESERVOIR WITH CLEAN OIL WILL HELP PREVENT EXTENDED CRANK TIME FROM AIR ENTERING THE HIGH PRESSURE OIL SYSTEM UPON ASSEMBLY. 1463 - 2009 F-SUPER DUTY - CARGO HOOK REPLACEMENT ON FACTORY SPRAY IN BEDLINERS ON 2009 F-SUPER DUTY UNITS WITH THE OPTIONAL SPRAY IN BEDLINER. THE BEDLINER MATERIAL IS SPRAYED IN AT THE ASSEMBLY PLANT. WHEN THE MATERIAL IS BEING APPLIED THE CARGO HOOKS ARE ALSO COVERED WITH THE BEDLINER MATERIAL. IF A CARGO HOOK IS BEING REPLACED ON A UNIT WITH THE FACTORY SPRAY IN BEDLINER THE CARGO HOOKS AND FASTENERS MAY BE REPLACED AS A SET SO THEY WILL MATCH. IMPORTANT - WHEN REMOVING CARGO HOOKS THE BEDLINER MATERIAL NEEDS TO BE CUT AROUND THE CARGO HOOK TO AVOID PULLING UP EXCESSIVE BEDLINER MATERIAL. 1462 - 2007-2008 VARIOUS VEHICLES - SATELLITE DIGITAL AUDIO RECEIVER SYSTEM (SDARS) LOW VOLUME AND/OR DTC U0196 AND/OR DVD WILL NOT PLAY OR EJECT THE DISC. SOME 2007-2008 VEHICLES EQUIPPED WITH REAR DIGITAL VIDEO DISC (DVD)/REAR ENTERTAINMENT MODULE (RETM), MAY EXHIBIT LOW VOLUME WHILE USING THE SATELLITE DIGITAL AUDIO RECEIVER SYSTEM (SDARS) AND/OR AUDIO CONTROL MODULE(ACM) DTC U0196, AND/OR RETM/DVD WILL NOT PLAY OR EJECT THE DISC. IF YOU ENCOUNTER THIS CONCERN, FIRST REMOVE AND REINSTALL THE F3 FUSE FROM THE SMART JUNCTION BOX (SJB) ON EXPEDITION, NAVIGATOR, EXPLORER, MOUNTAINEER, EDGE, MKX, TAURUS X, TAURUS, SABLE, F-SERIES SUPERDUTY / F4 FUSE FROM THE CENTRAL JUNCTION BOX (CJB) ON F150 AND MARK LT / F11 FUSE FROM THE SJB ON FIVE HUNDRED, MONTEGO AND RETEST. IF THE SYSTEM OPERATES NORMALLY, NO FURTHER SERVICE IS REQUIRED. IF THE CONCERN IS NOT REPAIRED USE THE WORK SHOP MANUAL, SECTION 415-00 FOR ADDITIONAL DIAGNOSTICS. 1443 - ANNOUNCING A NEW OASIS SYMPTOM CODE: 625000 EXTENDED IDLE SHUTDOWN. A NEW OASIS SYMPTOM CODE, 625000 EXTENDED IDLE SHUTDOWN UNDER THE DRIVABLITY CATEGORY, HAS BEEN ADDED REGARDING THE EXTENDED IDLE SHUTDOWN FUNCTION. THIS SYMPTOM CODE IS INTENDED TO DESCRIBE A VEHICLE EQUIPPED WITH AN EXTENDED IDLE SHUTDOWN FEATURE WHICH IS NOT SHUTTING DOWN AS EXPECTED. 1441 - RANGE INHIBIT LIGHT ON INSTRUMENT CLUSTER - NO ILLUMINATION - 2009 F650/750 BUILT BETWEEN 6/2/2008 - 6/26/2008 SEE TSB 08-19-12 FOR DETAIL 1425 - 6.0L HARD START/ NO START LOW INJECTOR CONTROL PRESSURE DIAGNOSIS SERVICE TIP PLEASE FAMILIARIZE YOURSELF WITH THE UPDATED HIGH PRESSURE OIL SYSTEM DIAGNOSTICS IN TSB 08-18-6. REMINDER: IF THE IPR VALVE SCREEN HAS FOREIGN MATERIAL, THEN REMOVE THE FOREIGN MATERIAL AND CONTINUE WITH IPR DIAGNOSTICS. IF THE IPR VALVE SCREEN IS FOUND TO BE DAMAGED THEN INSTALL A NEW IPR VALVE. THE PRESENCE OF FOREIGN MATERIAL ON THE SCREEN DOES NOT WARRANT HIGH PRESSURE PUMP OR IPR VALVE REPLACEMENT. 1420 - 2008 F-SUPER DUTY - 6.4L DIESEL ENGINE TICKING / TAPPING NOISE SEE TSB 08-19-05 FOR DETAIL 1387 - 2005-2007 F-SUPER DUTY, 2005-2008 E-SERIES AND 2005 EXCURSION - 6.0L HARD START / LONG CRANK / NO START - LOW INJECTOR CONTROL PRESSURE (ICP) SEE TSB 08-18-06 FOR DETAIL 1328 - 2008 LCF - HARD START, STUMBLE WITH ENGINE OIL TEMPERATURES (EOT) BETWEEN 68 - 122 DEGREES F (20 - 50 DEGREES C). SEE TSB 08-17-01 FOR DETAIL 1314 - ATTENTION DIESEL TECHNICIANS AND SERVICE MANAGEMENT PLEASE TAKE A MOMENT TO FAMILIARIZE YOURSELF WITH THE UPDATES TO TSB 08-16-13. THE TSB HAS BEEN UPDATED TO CLARIFY WHAT ACTIONS TO TAKE WHEN THERE IS CORROSION OR PITTING ON THE CENTER HOUSING FLANGE, HUB OR TURBINE HOUSING. WE HAVE ALSO UPDATED THE TURBO DRAIN TUBE INSPECTION. THANK YOU. 1313 - 1999-2008 7.3L/6.0L/6.4L/4.5L DIESEL - CLEAN THE CHARGE AIR COOLER (CAC) SYSTEM AFTER CERTAIN TURBO OR ENGINE FAILURES - SERVICE TIP ON A 7.3L, 6.0L, 6.4L, OR 4.5L DIESEL EQUIPPED VEHICLE IF THE TURBOCHARGER IS REPLACED FOR AN INTERNAL OIL LEAK OR COMPRESSOR SHAFT FAILURE, THE CHARGE AIR COOLER (CAC) SHOULD BE CHECKED FOR OIL CONTAMINATION AND CONSEQUENTLY CLEANED IF CONTAMINATION IS FOUND. THE CAC SHOULD ALSO BE INSPECTED AND CLEANED OF OIL, FUEL, OR METAL CONTAMINATION AFTER AN ENGINE FAILURE THAT MAY HAVE PUSHED OIL, FUEL, OR METAL INTO THE CAC DUE TO EXCESSIVE CRANKCASE PRESSURE. A THOROUGH CLEANING OF THE CAC SYSTEM IS NECESSARY TO PREVENT ENGINE DAMAGE OR DRIVABILITY CONCERNS. REFER TO THE WORKSHOP MANUAL SECTION 303-12 FOR PROPER CAC CLEANING PROCEDURES. IF EXHAUST SMOKE IS OBSERVED AFTER ENGINE REPAIRS AND THE CAC CLEANING HAVE BEEN COMPLETED REFER TO SYMPTOM CHART 8 IN THE PCED MANUAL. 1312 - 2008 LCF - MIL ON WITH UNKNOWN DTC 000 OR 0000. 2008 LCF VEHICLES MAY EXHIBIT A CHECK ENGINE LIGHT ON WITH AN UNKNOWN DTC 000 OR 0000 DISPLAYED. THIS CONDITION CAN BE CAUSED BY SCAN TOOL SOFTWARE OR ECU CALIBRATION NOT AT THE LATEST LEVELS. ENSURE MASTER DIAGNOSTIC SCAN TOOL SOFTWARE IS AT THE LATEST LEVEL (REVIEW PTS FOR LATEST SOFTWARE) AND RECHECK FOR DTCS. IF A RECOGNIZED DTC IS NOW RETRIEVED, PERFORM DIAGNOSTICS THROUGH NORMAL WSM / PC/ED DIRECTIONS/PP TESTS. IF 000/0000 DTC IS STILL RETRIEVED WITH LATEST LEVEL SOFTWARE, PERFORM AN ECM CALIBRATION UPDATE THROUGH NETS. SELECT THE "REFLASH - INSTALL NEW CALIBRATION" FUNCTION OF THE "GET" PROCESS. IF A RECOGNIZED DTC IS NOW RETRIEVED, PERFORM DIAGNOSTICS THROUGH NORMAL WSM / PC/ED DIRECTIONS/PP TESTS 1308 - 2003-2007 F-SUPER DUTY/2003-2005 EXCURSIONS/2004-2008 E-350/450 - 6.0L TURBOCHARGER CARBON DEPOSIT DIAGNOSTICS AND SERVICE TIPS SEE TSB 08-16-13 FOR DETAIL 1302 - 2008 LCF - CAC HOSE CONTACTING UPPER RADIATOR HOSE SEE TSB 08-16-11 FOR DETAIL 1300 - 2003-2008 MULTIPLE VEHICLES - MISFIRE, LACK OF POWER, BUCK / JERK, EXCESSIVE SMOKE, CRANK/NO START - 6.0L ENGINE - DIAGNOSTICS FOR FUEL SYSTEM - SERVICE TIPS SEE TSB 08-16-09 FOR DETAIL 1296 - 2008-2009 LCF - EXHAUST REGENERATION CONDITIONAL REQUIREMENTS 2008-2009 LCF VEHICLES REQUIRE SPECIFIC OPERATIONAL CONDITIONS FOR DIESEL PARTICULATE FILTER (DPF) EXHAUST REGENERATION TO OCCUR: MINIMUM SPEED OF 1 MPH (1.6KM/H) IS REQUIRED FOR DPF REGENERATION TO OCCUR. IF VEHICLE SPEED DROPS BELOW 1 MPH (1.6KM/H) DURING REGENERATION, THE PROCESS WILL GO INTO A HOLD MODE FOR UP TO 5 MINUTES OR UNTIL THE TRUCK BEGINS TO MOVE AGAIN. IF THE TRUCK DOES NOT ACHIEVE MORE THAN 1 MPH (1.6KM/H) WITHIN THE 5 MINUTE TIME, REGENERATION IS CANCELED. PLEASE REFER TO THE OWNERS GUIDE SECTION, "MAINTENANCE AND SPECIFICATIONS", FOR FURTHER DPF REGENERATION INFORMATION. 1292 - 2007 F-STRIPPED CHASSIS MOTORHOME - CRUISE CONTROL INOPERATIVE SOME 2007 F-STRIPPED CHASSIS MOTORHOMES BUILT ON 10/12/07 UP TO AND INCLUDING 10/31/07, MAY EXHIBIT AN INOPERATIVE CRUISE CONTROL DUE TO A LACK OF VOLTAGE SUPPLY FROM FUSE #27 LOCATED IN THE POWER DISTRIBUTION JUNCTION BOX(PDJB). INSPECT ALL CONNECTIONS AT PDJB, REFERENCING WIRING DIAGRAM BOOK SECTION 5 AND 31 TO ENSURE VOLTAGE SUPPLY AND CONNECTIONS FOR FUSE #27 ARE PRESENT AND SECURE. IF ALL CONNECTIONS AND VOLTAGE SUPPLY ARE PRESENT, CONTINUE WITH NORMAL DIAGNOSTICS IN WORK SHOP MANUAL SECTION 310-03. 1289 - 2008 F-SUPER DUTY 6.4L DIESEL ENGINE - CYLINDER CONTRIBUTION DIAGNOSTICS SEE TSB 08-16-07 FOR DETAIL 1280 - 2008 F-SUPER DUTY - 6.4L - VEHICLES BUILT BEFORE 4/23/2007 - ELECTRONIC THROTTLE CONTROL PEDAL REPLACEMENTS SEE TSB 08-16-02 FOR DETAIL 1279 - 2008 F-SUPER DUTY - 6.4L - VEHICLES BUILT BETWEEN 1/3/2008 AND 6/25/2008 - DIAGNOSTIC TROUBLE CODES P0128, P0196, P1335, P0404, P0406, P246C AND P2463 SEE TSB 08-16-01 FOR DETAIL 1276 - 2008 F650/F750 - CATERPILLAR EXHAUST REGENERATION CONDITIONAL REQUIREMENTS 2008 F650/F750 CATERPILLAR EQUIPPED VEHICLES REQUIRE SPECIFIC OPERATIONAL CONDITIONS FOR EXHAUST REGENERATION TO OCCUR: MINIMUM SPEED OF 20 MPH (32KM/H) IS REQUIRED FOR ACTIVE REGENERATION TO OCCUR. IF VEHICLE SPEED DROPS BELOW 5 MPH (8KM/H) DURING REGENERATION, THE PROCESS CANCELS WITHIN 3 MINUTES. REINITIATE BY RETURNING TO MINIMUM 20 MPH (32KM/H). SOOT LOAD LEVELS 1 OR HIGHER, MINIMUM SPEED IS REDUCED TO 5 MPH (8KM/H). IF THE VEHICLE SPEED FALLS BELOW TRIP POINT, SYSTEM ENTERS SOFT SHUTDOWN FOR 3 MINUTES. ENHANCED PASSIVE PLUS (EPP) CONTROLS SOOT LOAD DURING EXTENDED ENGINE OPERATIONS AT LOW IDLE. (REFERENCE CATERPILLAR OPERATION AND MAINTENANCE MANUAL FOR FURTHER DETAILS) REGENERATION TIMES GENERALLY ARE 10-30 MINUTES DEPENDING UPON SOOT LOAD LEVEL, TIMES MAY VERY DEPENDING ON OPERATIONAL CONDITIONS. 1273 - 2007-2008 F-SERIES MOTORHOME - CHASSIS LEAN SOME 2007-2008 F-SERIES MOTORHOMES MAY EXPERIENCE A CHASSIS LEAN CONDITION ON ONE OR MORE CORNERS, UPON THE INSTALLATION OF THE COACH. CHASSIS LEAN CONCERNS SHOULD FIRST BE DIRECTED TO THE COACH BUILDER TO ENSURE ALL BUILD SPECIFICATION MATCH THE CHASSIS REQUIREMENTS. MODIFYING THE CHASSIS SUSPENSION MAY NOT CORRECT A CONDITION CREATED BY THE COACH BUILDER AND SHOULD NOT BE PERFORMED WITHOUT THE COACH BUILDER'S AUTHORIZATION. 1247 - A NEW COMPRESSION TEST ADAPTER IS NOW AVAILABLE FOR FORD TRITON 3V ENGINES BUILT AFTER 10/2007 EQUIPPED WITH 12MM SPARK PLUGS. ORDER PART NUMBER STA73111 THROUGH THE ROTUNDA TECHNICIAN TOOL PROGRAM ON PTS, OR CALL 800-ROTUNDA OPTION 6. THE ADAPTER FITS BOTH 12MM AND 16MM SPARK PLUG HOLES AND IS EQUIPPED WITH QUICK-DISCONNECT COMPATIBLE WITH MANY COMPRESSION TESTERS. 1238 - 2004-2009 MEDIUM DUTY F-650/750 TRUCKS BUILT UP TO AND INCLUDING 7/9/2008 - AIR CONDITIONING VENTING DUE TO R-134A OVERFILL. SOME 2004-2009 MEDIUM DUTY F-SUPER DUTY 650/750 VEHICLES BUILT UP TO AND INCLUDING 7/9/2008, MAY EXHIBIT REFRIGERANT VENTING, POOR PERFORMANCE OR FREEZE UP IN WARMER CLIMATES. THIS MAY BE THE RESULT OF AN OVERFILLED R134A REFRIGERANT CONDITION. EVACUATE AND RECHARGE THE SYSTEM FOLLOWING WORKSHOP MANUAL SECTION 412-00, REDUCING THE AMOUNT OF REFRIGERANT TO 38 OZ. (1.07 KG) FROM 42 OZ. (1.19 KG). 1237 - 2008 F250-550 6.4L DIESEL RADIATOR REPLACEMENT VENTURI TEE INSTALLATION SOME 2008 F-SUPER DUTY 250-550 VEHICLES EQUIPPED WITH A 6.4L DIESEL ENGINE MAY REQUIRE A RADIATOR REPLACEMENT. AFTER FOLLOWING WORKSHOP MANUAL (WSM), 303-03 AND THE RADIATOR HAS BEEN IDENTIFIED AS THE CAUSE OF THE COOLANT LEAK AND IS TO BE REPLACED, IT IS NECESSARY TO ALSO INSTALL THE RADIATOR/VENTURI TEE SERVICE KIT 8C3Z-8B379-B. USE THE INSTRUCTION SHEET PROVIDED WITH THE KIT FOR PROPER INSTALLATION OF THE KIT. 1226 - A REVIEW OF WARRANTY RETURNED 6.0L HIGH PRESSURE PUMPS HAS FOUND MANY TO BE NOT DEFECTIVE. PLEASE REFER TO TSB 08-09-09 FOR COMPLETE HIGH PRESSURE FUEL SYSTEM DIAGNOSTICS. NOTE: IF THE IPR VALVE SCREEN HAS FOREIGN MATERIAL, THEN REMOVE THE FOREIGN MATERIAL AND CONTINUE WITH IPR DIAGNOSTICS IN TSB 06-13-03 OR HIGH PRESSURE FUEL SYSTEM TSB 08-09-09. IF THE IPR VALVE SCREEN IS FOUND TO BE DAMAGED THEN INSTALL A NEW IPR VALVE. THE PRESENCE OF DEBRIS ON THE SCREEN DOES NOT WARRANT HPP OR IPR VALVE REPLACEMENT. PUBLICATIONS ARE BEING UPDATED TO REFLECT THIS. 1206 - 2007-2008 VARIOUS VEHICLES - INTERMITTENT TPMS LIGHT WITH DTC'S B2872 AND B287A - CELL PHONE CHARGERS AND RF INTERFERENCE SOME 2007-2008 VEHICLES EQUIPPED WITH AN SPDJB MAY EXHIBIT AN INTERMITTENT TPMS LIGHT. DTC B2872 OR DTCS B2872/B287A MAY NOT IDENTIFY FAILED PARTS AND REPLACEMENT MAY LEAD TO REPEAT REPAIRS. SOME CELL PHONE CHARGERS CAN CREATE RF INTERFERENCE THAT DEGRADES TPMS PERFORMANCE. A DEVICE KNOWN TO CAUSE THE ISSUE IS A NAME BRAND CHARGER - MODEL MOTMINIVPC BUILT BEFORE 2007. TO IDENTIFY CHARGER, CHECK MODEL/SERIAL NUMBER ON THE PRODUCT TAG, THE 2 DIGIT YEAR FOLLOWS THE LETTERS "DC" - DC06XXXXXX. THIS ISSUE MAY BE CAUSED BY OTHER CHARGING DEVICES ALSO. ASK CUSTOMER TO PROVIDE THE CAR CELL PHONE CHARGER (OR SIMILAR DEVICE), ALONG WITH PHONE COMPLETELY DISCHARGED TO PERFORM A ROADTEST. IF DIAGNOSIS INDICATES CHARGER CAUSES INTERMITTENT TPMS LIGHT, ADVISE CUSTOMER TO OBTAIN A NEW CHARGER OR TO USE A DIFFERENT POWERPOINT LOCATION. 1203 - SOME 1997 THROUGH 2003 MY 7.3L VEHICLES MAY EXHIBIT A PHANTOM P0284, P0281, P0278, P0275, P0272, P0269, P0266, AND/OR P0263 DIAGNOSTIC TROUBLE CODE (DTC) SOME 1997 THROUGH 2003 MY 7.3L VEHICLES MAY EXHIBIT PHANTOM P0284, P0281, P0278, P0275, P0272, P0269, P0266, AND/OR P0263 DIAGNOSTIC TROUBLE CODES (DTC) WITHOUT DRIVABILITY SYMPTOMS IN CYLINDER CONTRIBUTION TEST (CCT) ON VEHICLES EQUIPPED WITH A NEW STYLE (GRAY) CMP SENSOR. THE NEW STYLE SENSOR WOULD HAVE BEEN INSTALLED UNDER SAFETY RECALL 07S57. ENGINEERING IS CURRENTLY WORKING ON A RESOLUTION TO ELIMINATE THE PHANTOM CODES. 1183 - 2008 F-SUPER DUTY - DISTANCE TO EMPTY (DTE) NOT ACCURATE ON 2008 F-SERIES SUPER DUTY VEHICLES, DISTANCE TO EMPTY (DTE) MAY SHOW 50 MILES TO EMPTY AND THE "LOW FUEL" MESSAGE MAY COME ON WITH THE INDICATED FUEL TANK LEVEL MORE THAN 1/8 (POSSIBLY AS MUCH AS 3/4) FULL. THIS CONDITION IS NORMAL, AND THE RESULT OF CUSTOMER SUBJECTING VEHICLE TO CONDITIONS WHICH ADVERSELY AFFECT THE VEHICLE'S FUEL ECONOMY (SUCH AS SNOW PLOWING, PTO, TOWING, ETC). DURING THIS TYPE OF OPERATION, IT IS POSSIBLE TO GET LOW ENOUGH MPG READINGS FOR A LONG ENOUGH TIME, TO GET THE "LOW FUEL" WARNING TO ACTIVATE WITH A SIGNIFICANT AMOUNT OF FUEL REMAINING IN THE TANK. NOTE: FORD HAS PROVIDED A RESERVE OF FUEL STILL AVAILABLE WHEN THE GAUGE READS E TO PROTECT THE CUSTOMER FROM RUNNING OUT OF FUEL (AS MUCH AS 5 GALLONS). AFTERMARKET ITEMS SUCH AS FUEL TANKS, NON-OEM TIRE SIZES, ETC. WILL ALSO AFFECT DTE. 1149 - 2004-2007 F-SUPER DUTY, 2004-2005 EXCURSION, AND 2004-2007 F-650/750 - LACK OF A/C COOLING SEE TSB 08-13-05 FOR DETAIL 1144 - 2008 F-SUPER DUTY - 6.4L - VEHICLES BUILT BETWEEN 8/3/2007 AND 1/3/2008 - MODULE REPROGRAMMING SEE TSB 08-13-03 FOR DETAIL 1143 - 2008 F-SUPER DUTY - 6.4L - VEHICLES BUILT PRIOR TO 8/3/2007 - MODULE REPROGRAMMING SEE TSB 08-13-02 FOR DETAIL 1139 - 2004-2008 F650/F750 MODULE COMMUNICATION CONCERNS - LACK OF VOLTAGE SUPPLY TO MODULES SOME 2004-2008 F650/F750 MEDIUM DUTY VEHICLES MAY EXPERIENCE AN INTERMITTENT MODULE COMMUNICATION CONCERN DURING CRANKING. THIS CONDITION CAN BE CAUSED BY A DROP IN SUPPLY VOLTAGE TO THE MODULE IN QUESTION AND MAY SET A COMMUNICATIONS DTC. WORK SHOP MANUAL (WSM) SECTION 303-06A-B-C, 414-00 AND 414-01 SHOULD BE REVIEWED TO ENSURE BATTERY/CHARGING AND STARTING SYSTEMS ARE OPERATING PROPERLY. IF NORMAL WSM DIAGNOSTICS DO NOT REVEAL A CONCERN, INSPECT FOR MODIFICATIONS TO THE BATTERY CABLING FROM THE BATTERY TO THE STARTER OR FROM THE STARTER TO THE BATTERY JUNCTION BOX. INSPECT BATTERY SUPPLY VOLTAGE TO THE MODULE IN QUESTION DURING CRANKING, AND ENSURE EACH CIRCUIT SUPPLYING VOLTAGE TO THE MODULE IS MEASURED FOR ANY VOLTAGE DROP. REPAIR ALL WIRING ISSUES USING WIRING DIAGRAM BOOKLET SECTION 5. 1096 - 2004-2007 MEDIUM DUTY F-650/750 - AIR CONDITIONING VENTING DUE TO R-134A OVERFILL SOME 2004-2007 MEDIUM DUTY F-650/750 VEHICLES MAY EXHIBIT AIR CONDITIONING VENTING, POOR PERFORMANCE OR FREEZE UP IN WARMER CLIMATES, THIS MAY BE THE RESULT OF OVERFILL OF R134A. EVACUATE AND RECHARGE THE SYSTEM IN ACCORDANCE OF THE WORKSHOP MANUAL SECTION 412-00 REDUCING FILL TO 1.02 KG (36 OZ)FROM 1.19 KG (42 OZ). 1085 - 2004-2007 F-650/F-750 - 6.0L - HARD START/LONG CRANK /NO START - LOW ICP SEE TSB 08-12-08 FOR DETAIL 1076 - ANNOUNCEMENT: NEW 6.4L SHORT BLOCK ASSEMBLIES, 8C3Z-6009-A ARE NOW AVAILABLE. DEALERSHIPS CAN PLACE ORDERS DIRECTLY TO FORD, THROUGH DOES II. A SHORT BLOCK ASSEMBLY SHOULD BE CONSIDERED WHEN MAKING DAMAGED ENGINE REPAIRS VS. COMPLETE ENGINE ASSEMBLIES. 1075 - ELECTRICAL MOTORS AND MODULES SOME COMPONENTS, ESPECIALLY ELECTRICAL MOTORS AND MODULES, LOOK THE SAME AND COULD EVEN BE CROSS INSTALLED IN DIFFERENT LOCATIONS. PLEASE TAKE CARE TO AVOID SWAPPING ELECTRICAL MOTORS OR MODULES IN SERVICE AS IT COULD RESULT IN OPERATIONAL DIFFICULTIES. EVEN THOUGH A PART LOOKS THE SAME AND CAN BE INSTALLED, UNLESS SPECIFICALLY INTENDED FOR THAT FUNCTION, IT MAY NOT OPERATE AS DESIGNED. ALWAYS CONSULT THE PARTS CATALOG FOR THE YEAR/MODEL TO DETERMINE THE PROPER PART APPLICATION FOR THE SPECIFIC REPLACEMENT NEEDED. FOR EXAMPLE: THE GLASS DRIVE SUNSHADE MOTORS ON VISTA ROOFS APPEAR IDENTICAL BUT FUNCTION DIFFERENTLY. 1072 - 2004-2008 F150/2006-2008 MARK LT/2005-2008 EXPEDITION/NAVIGATOR/F-SUPER DUTY 5.4L 3V ENGINE - MISC DRIVABILITY CONCERNS/VERIFY SCHEDULED MAINTENANCE COMPLETE SOME 2004-2008 F150 / 2006-2008 MARK LT / 2005-2008 EXPEDITION/NAVIGATOR/F-SUPER DUTY VEHICLES WITH 5.4L 3V ENGINE WITH GREATER THAN 60,000 MILES, THAT ARE SUBJECTED TO SPECIAL OPERATING CONDITIONS, MAY EXHIBIT MISFIRE DTCS AND IGNITION SYSTEM RELATED DRIVABILITY CONCERNS UNDER HIGH-LOAD OR WIDE OPEN THROTTLE (WOT). SPECIAL OPERATING CONDITIONS ARE DEFINED AS EXTENSIVE IDLING AND/OR LOW-SPEED DRIVING FOR LONG DISTANCES AS IN HEAVY COMMERCIAL USE SUCH AS DELIVERY, HEAVY TOWING, TAXI, PATROL CAR OR LIVERY. BEFORE ATTEMPTING REPAIRS, VERIFY RECOMMENDED 60,000 MILE SCHEDULED MAINTENANCE SERVICE HAS BEEN PERFORMED WHICH INCLUDES SPARK PLUG REPLACEMENT. REFER TO TSB 08-07-06 WHICH PROVIDES UPDATED SPARK PLUG REMOVAL PROCEDURE. IF SPARK PLUG REPLACEMENT DOES NOT CORRECT THE CONDITION CONTINUE WITH NORMAL PC/ED DIAGNOSTIC ROUTINES. 1038 - 2006-2007 LCF HIGH PRESSURE OIL SYSTEM LEAK - DTC 335 - HARD START/NO START - LOW POWER SEE TSB 08-11-09 FOR DETAIL 1031 - 2008 F650/F750 CHECK ENGINE LIGHT ON WITH J1938 DTC 111-1, 111-2, AND 111-17. AS STATED IN OASIS MESSAGE SSM 20092, SOME 2008 F650/F750 TRUCKS MAY TURN THE CHECK ENGINE LIGHT ON (WITH A POSSIBLE STOP ENGINE LIGHT) AT LOW COOLANT LEVELS. CHECK FOR PROPER COOLANT LEVEL PRIOR TO PERFORMING ANY PART REPLACEMENT. THE COOLANT LEVEL MUST BE SET TO THE MIDDLE OF THE UPPER SIGHT GLASS FOR NORMAL OPERATING TEMPERATURES. THIS CAN RESOLVE A CHECK ENGINE LIGHT ON FOR COOLANT LEVEL WARNING ISSUE WITHOUT REPLACING THE COOLANT LEVEL SENSOR. 1030 - ANNOUNCING THE EXPANSION OF THE EXISTING DIESEL ENGINE PRIOR APPROVAL PROGRAM TO INCLUDE SELECTED 6.0L DIESEL COMPONENTS. EFFECTIVE WITH REPAIRS DATED JUNE 1, 2008, ANY REPAIR THAT REQUIRES REPLACEMENT OF ANY OF THE FOLLOWING 6.0L COMPONENTS WILL REQUIRE PRIOR APPROVAL FROM THE TECHNICAL HOTLINE. 6K682 TURBO ASSEMBLY, 9A543-HP OIL PUMP, 6049-CYLINDER HEAD/6051-HEAD GASKET, 9P456-EGR COOLER AND 6A642-OIL COOLER. WHEN DIAGNOSTICS LEAD TO THE 6049-CYLINDER HEAD OR 6051-HEAD GASKET THE PRIOR APPROVAL MUST BE OBTAINED BEFORE REMOVING THE CYLINDER HEAD(S). THESE NEW REQUIREMENTS ARE FOR ALL NON-LEVEL ONE DEALERSHIPS. LEVEL ONE DEALERSHIPS ARE EXEMPT. SEE EFC0200609 FOR MORE DETAILS. 1021 - 2008 F-SUPER DUTY - POWER WINDOW NOISE - BUILT BEFORE 7/31/2007 SEE TSB 08-11-05 FOR DETAIL 1015 - 2003-2005 EXCURSION, 2003-2007 F-SUPER DUTY, 2004-2008 E-SERIES - COOLANT LOSS - 6.0L SEE TSB 08-11-03 FOR DETAIL 1012 - BEGINNING MAY 19TH 2008 A NEW WARRANTY PART COVERAGE LOOK-UP TOOL IS AVAILABLE ON GLOBAL OASIS TECHNICIAN WEB VIEWS THE NEW TOOL COMBINES THE INQUIRY PROCESS FOR BOTH WARRANTY & ESP. IN ADDITION TO ESP, THIS TOOL WILL PROVIDE WARRANTY COVERAGE VERIFICATION FOR * BASIC WARRANTY * BUMPER-TO-BUMPER * POWERTRAIN WARRANTY * SAFETY WARRANTY * CORROSION WARRANTY * DIESEL ENGINE WARRANTY * UNIQUE HYBRID COMPONENTS WARRANTY * EMISSIONS WARRANTY (FEDERAL AND CALIFORNIA) REFER TO EFC 0200608 FOR DETAILS 1003 - 2008 F-SUPER DUTY - NOISE/POP HEARD/FELT UNDER DRIVER-SIDE FLOOR PAN DURING AGGRESSIVE VEHICLE TURNING SOME 2008 F-SUPER DUTY VEHICLES MAY EXHIBIT A POPPING NOISE HEARD/FELT UNDER DRIVER FLOOR PAN DURING AGGRESSIVE TURNING, MORE NOTICEABLE COLD. 1)VEHICLE BUILD DATE BEFORE 6/1/07 APPLY MULTI-PURPOSE GREASE(XL-5) TO BODY MOUNT-TO-FRAME BRACKET TOP INTERFACE, ALL LOCATIONS (DO NOT REMOVE MOUNTS. 2)IF CAB REMOVED, RECHECK WORK/CLEARANCES {WSM,502-02}AND CHECK BODY MOUNT-TO-FLOOR PAN FASTENER TORQUE{103 NM/76 FT LB}. 3)VALIDATE 4X4 LOCKING HUB-SYS OPERATING {WSM,308-07A}. VALIDATE 4X4 SYSTEM OFF(NOISE TURNING WHILE 4X4 ENGAGED IS NORMAL) CONFIRM LOCKING HUBS IN AUTO AND NOT LOCKED POSITION. 4)INSPECT CLEARANCE,FLOOR PAN TO FRAME RAIL TOP LHS/RHS FROM A-PILLAR BODY MOUNT REARWARD. ENSURE NO PARTS GROUNDING OUT TO FLOOR PAN. 5)EXAMINE FRONT BRAKE ROTOR DUST SHIELDS DON'T INTERFERE WITH OTHER COMPONENTS. ISSUE UNDER INVESTIGATION, SUBMIT DETAIL GCR 1000 - 1999-2008 7.3L/6.0L/6.4L/4.5L DIESEL - CLEAN THE CHARGE AIR COOLER (CAC) SYSTEM AFTER CERTAIN TURBO OR ENGINE FAILURES - SERVICE TIP IF THE TURBOCHARGER IS REPLACED ON A 4.5L, 6.0L, 6.4L OR 7.3L DIESEL EQUIPPED VEHICLE FOR AN INTERNAL OIL LEAK OR COMPRESSOR SHAFT FAILURE, THE CHARGE AIR COOLER (CAC) SHOULD BE CHECKED FOR OIL CONTAMINATION AND CONSEQUENTLY CLEANED IF OIL CONTAMINATION IS FOUND. THE CAC SHOULD ALSO BE INSPECTED AND CLEANED OF OIL OR METAL CONTAMINATION AFTER AN ENGINE FAILURE THAT MAY HAVE PUSHED OIL/METAL INTO THE CAC DUE TO EXCESSIVE CRANKCASE PRESSURE. A THOROUGH CLEANING OF THE CAC SYSTEM IS NECESSARY TO PREVENT FURTHER DRIVABILITY OR ENGINE CONCERNS. UPDATED CHARGE AIR COOLER (CAC) CLEANING PROCEDURES ARE NOW AVAILABLE FOR 2008 MODEL YEAR SUPER-DUTIES EQUIPPED WITH 6.4L DIESEL ENGINES IN THE WORKSHOP MANUAL(WSM) SECTION 303-12. 0999 - 1999-2008 F-250 AND F-350 - MATCHING THE CORRECT 10.5 AXLE HOUSING AND PINION BEARING WHEN REPLACING 1999-2008 MY F250/350 10.5" REAR AXLE HOUSINGS MAKE SURE TO ORDER THE CORRECT PINION BEARINGS FOR THE HOUSING. THE 2008MY HOUSING IS ALL NEW AND REQUIRES A UNIQUE PINION GEAR TAIL AND HEAD BEARING, BE SURE TO ORDER 2008 PINION BEARINGS PER THE PARTS CATALOG. THE 2008MY HOUSING IS ALSO USED TO SERVICE OLDER MODEL VEHICLES, IF THE HOUSING NEEDS TO BE REPLACED. PINION BEARING SERVICE PARTS ARE STILL AVAILABLE FOR OLDER MODEL YEAR HOUSINGS. WHEN REPLACING PINION BEARINGS ALWAYS REPLACE THE CUP (RACE) AND BEARING AS AN ASSEMBLY. MIXING PRE-2008 BEARINGS WITH AN 2008 HOUSING OR VICE VERSA MAY RESULT IN CUSTOMER COMPLAINTS OF AXLE WHINE OR NOISE BECAUSE THE REQUIRED PRELOAD IS NOT ACHIEVED. 0998 - 2004-2008 F650/F750 SPICER MANUAL TRANSMISSION GEAR OIL IDENTIFICATION. SOME 2004-2008 SPICER MANUAL TRANSMISSION EQUIPPED F650/F750 VEHICLES MAY HAVE BEEN MISS-TAGGED WITH A LABEL ON THE TRANSMISSION FILL PLUG INDICATING SYNTHETIC TYPE FLUID IS PRESENT. TO PROPERLY IDENTIFY THE FLUID TYPE FOR THE TRANSMISSION, REVIEW THE FOLLOWING: ON LOW MILEAGE TRUCKS IT MAY BE POSSIBLE TO DETERMINE FLUID TYPE BY THE COLOR OF THE FLUID - AMBER INDICATES A MINERAL BASED FLUID - RED INDICATES A SYNTHETIC BASED FLUID. ON HIGHER MILEAGE VEHICLES, FLUIDS MAY TRANSITION TO A BROWNISH COLOR MAKING IT DIFFICULT TO IDENTIFY. CHECK FOR A LABEL PLACED ON TOP OF THE TRANS IDENTIFYING 80W90 GL1 FOR MINERAL BASED AND CD-50 FOR SYNTHETIC BASED FLUIDS. 0996 - FOR 2005 - 2008 VEHICLES WITH WITH CHROME BUMPER'S AND/OR RUNNING BOARDS AFTER THE WINTER SOME CUSTOMERS MAY EXPRESS A CONCERN OVER APPEARANCE ISSUES (RUST, DISCOLORING, FADING..) ON CHROME BUMPERS / RUNNING BOARDS. MOST BUMPERS / RUNNING BOARDS CAN BE RESTORED USING MOTORCRAFT BRIGHT METAL CLEANER ZC-15 PER THE CLEANING SECTION IN THE OWNERS GUIDE. THE WPAC EVALUATES AND CLEANS ALL RETURNS. BUMPERS / RUNNING BOARDS THAT CAN BE RESTORED BY CLEANING WILL BE SUBJECT TO CHARGE BACK. 0991 - 2008 F-SUPER DUTY - 6.4L - VEHICLES BUILT BETWEEN 1/3/2008 AND 5/5/2008 - DIAGNOSTIC TROUBLE CODES (DTCS) P0128, P0196, P1335, P0404 AND P0406 SEE TSB 08-10-02 FOR DETAIL 0987 - ANNOUNCING VENDOR PROGRAM 08V01 VENDOR PROGRAM 08V01:CERTAIN 2008 F650 AND F750 TRUCKS WITH ALLISON TRANSMISSION PARK PAWL ACTUATOR ASSEMBLY INSPECTION AND REPAIR. THE FOLLOWING HAS BEEN POSTED TO FMCDEALER.COM 0980 - 6.4L EGR REMOVAL TOOL DAMAGE CONCERNS SOME 6.4L EGR (303-1267) TOOLS MAY EXPERIENCE A STRIPPED BEARING RETAINING NUT. IF THE NUT BECOMES DAMAGED DURING EGR VALVE REMOVAL, INSPECT THE THREADED FORCING SCREW FOR DAMAGE AS WELL AND CALL ROTUNDA FOR REPLACEMENT COMPONENTS AT 1-800-ROTUNDA (768-8632) AND CHOOSE OPTION #5 AT THE PROMPT. DURING TOOL RE-ASSEMBLY REMEMBER TO USE LOC-TITE 262 AND NOTE THAT IT IS A LEFT HAND THREAD. PLEASE MAKE SURE THAT THE PILOT CUP TURNS FREELY AFTER RE-ASSEMBLY AS WELL. 0978 - 2005 EXCURSION / 2005-2008 F-SUPER DUTY - 5.4L / 6.8L - CORRECT PROCEDURE FOR CHECKING EVAP SYSTEM LEAKS ON 40 GALLON FUEL TANKS WHEN CHECKING FOR EVAP SYSTEM LEAKS ON 2005-2008 F-SUPER DUTY, 2005-2008 ECONOLINE OR 2005 EXCURSION VEHICLES EQUIPPED WITH FUEL TANKS 40 GALLONS AND GREATER, IT IS RECOMMENDED TO RUN THE VEHICLES ON BOARD EVAP MONITOR TEST WITHIN THE OBDII DRIVE CYCLE TEST. IT IS NOT RECOMMENDED TO PERFORM THE IDS/SCAN TOOL EVAP TEST ON VEHICLES WITH 40 GALLON AND GREATER FUEL TANKS, THIS MAY RETURN ERRONEOUS/INACCURATE RESULTS. 0976 - SOME 2005-2007 F-SUPER DUTY / 2005-2008 E-SERIES / 2005 EXCURSION - 6.0L - HARD START / LONG CRANK / NO START - LOW INJECTOR CONTROL PRESSURE (ICP) SEE TSB 08-09-09 FOR DETAIL 0973 - USE ONLY MOTORCRAFT PM-3 FOR 3V ENGINE SPARK PLUG REMOVAL TSB 08-07-06 WAS RECENTLY PUBLISHED TO PROVIDE IMPORTANT PROCEDURE UPDATES TO REMOVE SPARK PLUGS FROM 4.6 3V / 5.4L 3V / 6.8L 3V ENGINES. IT IS IMPERATIVE THAT TECHNICIANS USE MOTORCRAFT CARBURETOR & TUNE-UP CLEANER, PART NUMBER PM-3, IN PLACE OF AEROKROIL PENETRATING OIL TO AID SPARK PLUG REMOVAL. PM-3 WAS TESTED EXTENSIVELY AND HAS PROVEN TO BE A SUPERIOR PRODUCT FOR THIS PROCEDURE. REFER TO THE TSB FOR ADDITIONAL SPARK PLUG REMOVAL DETAILS. 0969 - 2006-2007 F-53 MOTORHOME - AXLE NOISE (DANA S110/S130) SOME 2006-2007 F-53 MOTORHOMES BUILT ON OR BEFORE 2/1/2007 MAY PRODUCE A WHINE/GROWL NOISE COMING FROM THE REAR AXLE ASSEMBLY. DIAGNOSE AXLE NOISE USING WORK SHOP MANUAL (WSM) SECTION 205-00. IF INSPECTION OF INTERNAL COMPONENTS REVEAL NO WEAR CONCERNS, INSPECT AND ADJUST BACK LASH OF RING AND PINION 0.009"- 0.016" (0.23 - 0.41MM). IF NOISE PERSISTS AFTER BACK LASH ADJUSTMENT, REPLACEMENT OF RING AND PINION (W/BEARINGS) MAY BE NECESSARY AS REFERENCED IN WSM SECTION 205-00. IF RING AND PINION IS REQUIRED, DO NOT REPLACE DIFFERENTIAL CASE (CROSS SHAFT HALF ASSEMBLY) IF INSPECTION OF CASE REVEALS NO DAMAGE OR WEAR 0968 - ANNOUNCING FIELD SERVICE ACTION 08B03 FULL BULLETIN UPDATE: FULL BULLETIN...CUSTOMER SATISFACTION PROGRAM 08B03 - CERTAIN 2008 MODEL YEAR F-350, 4X4, 10,001 LBS AND OVER GVW, 156" WHEEL BASE VEHICLES EQUIPPED WITH A TWO-PIECE DRIVE SHAFT - FUEL TANK STOPPER BRACKET INSTALLATION. REFER TO FMCDEALER.COM FOR DETAILS. 0967 - ANNOUNCING FIELD SERVICE ACTION - COMPLIANCE RECALL FULL BULLETIN - 08C04 UPDATE: FULL BULLETIN...COMPLIANCE RECALL 08C04 - CERTAIN 2008 MODEL YEAR F-250 AND F-350, 4X4, SINGLE REAR WHEEL, 10,000 LBS AND UNDER GVW, 156" WHEEL BASE VEHICLES EQUIPPED WITH A TWO-PIECE DRIVE SHAFT - FUEL TANK STOPPER BRACKET INSTALLATION. REFER TO FMCDEALER.COM FOR DETAILS. 0966 - 2005-2008 F250-550 SUPER DUTY MANUAL TRANS - CLUTCH PEDAL CONCERN SOME 2005-2008 F250-550 SUPER DUTY VEHICLES WITH A MANUAL TRANSMISSION MAY EXHIBIT A CLUTCH PEDAL CONCERN DESCRIBED AS "FALLS TO THE FLOOR", "CLUTCH PEDAL STAYS ON THE FLOOR", OR "CLUTCH PEDAL FEELS SPONGY". IF THE CONCERN IS DIAGNOSED AS THE CONTROL ASSEMBLY - CLUTCH HYDRAULIC ACTUATOR (BASE PART NUMBER 7C522), ENSURE THE HEAT SHIELD IS FULLY COVERING THE CLUTCH SLAVE CYLINDER END OF THE ASSEMBLY. IF THE HEAT SHIELDING IS NOT FULLY COVERING THE CLUTCH SLAVE CYLINDER, SLIDE THE HEAT SHIELDING TOWARD THE TRANSMISSION UNTIL THE FORWARD END OF THE SHIELD CONTACTS THE CYLINDER MOUNTING FLANGE AT THE TRANSMISSION HOUSING. 0963 - CONTACT 1-800-FORD-KEY FOR REMOTE START CONCERNS ON 2007 FREESTYLE, FIVE HUNDRED, MONTEGO, 2007 AND 2008 CROWN VICTORIA, GRAND MARQUIS, FUSION, FOCUS, MILAN, MKZ, MUSTANG, TOWN CAR, EXPEDITION, NAVIGATOR, EDGE, MKX, ESCAPE, MARINER, F-150, MARK LT, F-SUPER DUTY, RANGER, 2008 TAURUS, TAURUS X AND SABLE. FOR QUESTIONS ABOUT INSTALLING OR TROUBLESHOOTING ANY GENUINE FORD/LINCOLN/MERCURY REMOTE START OR VEHICLE SECURITY KIT, PLEASE CONTACT 1-800-FORD-KEY FOR ASSISTANCE. 0953 - 2008 F-SUPER DUTY, E-SERIES, AND F-53 MOTORHOME CHASSIS - 6.8L CRANKSHAFT DAMPER TOO LARGE FOR AFTERMARKET PTO SPIDER BRACKET. SOME F-SUPER DUTY, E-SERIES, AND F-53 MOTORHOME VEHICLES EQUIPPED WITH 6.8L ENGINE BUILT BETWEEN 9/27/2007 - 1/23/2008, HAVE A CRANKSHAFT DAMPER WITH AN INCORRECTLY SIZED POWERTRAIN TAKE OFF (PTO) PILOT BORE. AN AFTERMARKET PTO SPIDER BRACKET WILL NOT PROPERLY FIT. THE FUNCTION OF THE DAMPER IS NOT EFFECTED. ONLY AFTERMARKET USERS THAT WISH TO ATTACH A PTO SPIDER BRACKET WILL BE IMPACTED. PLEASE REFER TO http://WWW.FLEET.FORD.COM/TRUCKBBAS, QVM BULLETIN# Q-167 FOR FURTHER DETAILS. 0951 - 1999-2008 7.3L/6.0L/6.4L/4.5L DIESEL - CLEAN THE CHARGE AIR COOLER (CAC) SYSTEM AFTER CERTAIN TURBO OR ENGINE FAILURES - SERVICE TIP ON A 7.3L, 6.0L, 6.4L, OR 4.5L DIESEL EQUIPPED VEHICLE IF THE TURBOCHARGER IS REPLACED FOR AN INTERNAL OIL LEAK OR COMPRESSOR SHAFT FAILURE, THE CHARGE AIR COOLER (CAC) SHOULD BE CHECKED FOR OIL CONTAMINATION AND CONSEQUENTLY CLEANED IF OIL CONTAMINATION IS FOUND. THE CAC SHOULD ALSO BE INSPECTED AND CLEANED OF OIL OR METAL CONTAMINATION AFTER AN ENGINE FAILURE THAT MAY HAVE PUSHED OIL/METAL INTO THE CAC DUE TO EXCESSIVE CRANKCASE PRESSURE. A THOROUGH CLEANING OF THE CAC SYSTEM IS NECESSARY TO PREVENT FURTHER DRIVABILITY OR ENGINE CONCERNS. 0947 - 2008 E-SERIES, SUPER DUTY OR RANGER - NO CRANK, CRANK/NO START WITH P1260 DTC NON-PATS AND PATS KEY EQUIPPED. 2008 E-SERIES, SUPER DUTY OR RANGER HAVE PATS SYSTEMS AND KEYS AS OPTIONAL EQUIPMENT. ALL 2008 E-SERIES, SUPER DUTY OR RANGER (WITH OR WITHOUT PATS KEYS) REQUIRE A PATS "HANDSHAKE"(KEY CYCLE) BETWEEN THE IC AND THE PCM TO ENABLE STARTING AND WILL SET A P1260 IN THE PCM IF THIS ENCRYPTED COMMUNICATION DOES NOT OCCUR. IF THE INSTRUMENT CLUSTER (IC) OR THE PCM IS/OR HAS BEEN REPLACED (OR BOTH), THE PARAMETERS MUST BE RESET AFTER THE 10 MIN ACCESS HAS BEEN GRANTED. THIS PROCESS WILL INTRODUCE THESE MODULES TO EACH OTHER SO THEY CAN COMPLETE THE "HANDSHAKE" EACH TIME THE VEHICLE IS STARTED. IF THE PARAMETER RESET IS NOT COMPLETED THE VEHICLE WILL EXPERIENCE A PASSIVE ANTI-THEFT SYSTEM (PATS) NO-START WITH A P1260 DTC. THIS WILL OCCUR EVEN IF THE VEHICLE IS NOT EQUIPPED WITH PATS. REFER TO PASSIVE ANTI-THEFT SYSTEM PARAMETER RESET IN WSM 419-01-1. 0933 - 2008 F-SUPER DUTY 250-550 - TRAILER TOW RATINGS FOR 3.55 GEAR RATIO EQUIPPED VEHICLES. WHEN REFERENCING THE 2008 RV AND TRAILER TOWING GUIDE THE NEW 3.55 AXLE RATIO IS NOT LISTED. TO DETERMINE TOWING CAPABILITIES OF TRUCKS EQUIPPED WITH A 3.55 GEAR RATIO REFER TO THE 3.73 AXLE RATIO DATA (THE NEW 3.55 AXLE RATIO IS RATED THE SAME AS THE 3.73 RATIO FOR TOWING CAPACITIES). 0905 - ANNOUNCING SAFETY RECALL 08S04 ANNOUNCING SAFETY RECALL 08S04 - CERTAIN 2008 MODEL YEAR ECONOLINE E350 VEHICLES - DRIVESHAFT INSPECTION/REPLACEMENT. THE DEALER BULLETIN HAS BEEN POSTED TO FMCDEALER.COM. 0903 - 2008 E-SERIES/RANGER - NO CRANK, CRANK/NO START WITH P1260 DTC NON-PATS AND PATS KEY EQUIPPED. 2008 E-SERIES/RANGER HAVE PATS KEYS AS AN OPTIONAL SYSTEM. ALL 2008 E-SERIES AND RANGER (WITH OR WITHOUT PATS KEYS) REQUIRE A PATS "HANDSHAKE"(KEY CYCLE) BETWEEN THE IC AND THE PCM TO ENABLE STARTING AND WILL SET A P1260 IN THE PCM IF THIS ENCRYPTED COMMUNICATION DOES NOT OCCUR. IF THE INSTRUMENT CLUSTER (IC) OR THE PCM IS/OR HAS BEEN REPLACED (OR BOTH), THE PARAMETERS MUST BE RESET IN BOTH MODULES OR THE VEHICLE WILL EXPERIENCE A PASSIVE ANTI-THEFT SYSTEM (PATS) NO-START WITH A P1260 DTC. THIS WILL OCCUR EVEN IF THE VEHICLE IS NOT EQUIPPED WITH PATS. PATS VEHICLES AND NON-PATS VEHICLES HAVE PARAMETERS IN THE IC AND THE PCM AND THEY MUST BE RESET WHENEVER EITHER (OR BOTH) MODULE(S) IS (ARE) REPLACED. REFER TO PASSIVE ANTI-THEFT SYSTEM (PATS) PARAMETER RESET IN WSM 419-01-1. 0900 - 2008 F250-550 SUPER-DUTY 6.4L DIESEL - MESSAGE CENTER W/DTC P246C AND/OR P2463 SOME 2008 F250-550 SUPER-DUTY VEHICLES EQUIPPED WITH A 6.4L DIESEL ENGINE MAY EXHIBIT A CONTINUOUS DISPLAY OF DRIVE TO CLEAN IN THE INSTRUMENT CLUSTER MESSAGE CENTER WITH DIAGNOSTIC TROUBLE CODES(DTC) P246C: DPF RESTRICTION - FORCED LIMITED POWER AND/OR P2463: DPF RESTRICTION - SOOT ACCUMULATION. THIS IS DUE TO VOLTAGE BEING APPLIED TO POWER-TAKE-OFF(PTO) PCM PIN C1-30 WHEN PTO OPERATION OR STATIONARY ELEVATED IDLE CONTROL(SEIC) IS DISENGAGED/INACTIVE. 12 VOLTS MUST ONLY BE APPLIED TO PTO ECM PIN C1-30 WHEN PTO, STATIONARY ELEVATED IDLE CONTROL(SEIC) AND APPROPRIATE SAFETY ENABLERS (SEE QVM 162R1, PAGE 15 HTTPS://WWW.FLEET.FORD.COM/TRUCKBBAS/TOPICS/QVMP.HTML) ARE ACTIVATED. 0897 - 2008 F250-550 SUPER-DUTY - 6.4L DIESEL - TICKING,TAPPING NOISE, HOT ENGINE. SOME 2008 F250-550 SUPER-DUTY EQUIPPED WITH A 6.4L DIESEL ENGINE MAY EXHIBIT A RANDOM TICKING/TAPPING NOISE THAT IS MOST AUDIBLE ON A HOT ENGINE AND IS MOST NOTICEABLE AT THE REAR OF THE ENGINE AND INSIDE THE FRONT WHEEL WELLS. THE NOISE RESONATES THROUGH THE CYLINDER BLOCK AND OR HEADS IS HEARD AS A METALLIC TICKING OR TAPPING SOUND, LIKE A SPARK PLUG WIRE ARCING OR LIFTER TICK.THE TICKING OR TAPPING NOISE CAN COME AND GO AND HAS A NONRHYTHMIC PATTERN. ENGINEERING IS AWARE OF THIS NOISE AND HAS AN INVESTIGATION UNDERWAY. AT THIS TIME, THE NOISE IS CONSIDERED AS A NORMAL OPERATING CHARACTERISTIC OF THE ENGINE. THE NOISE HAS NO SHORT OR LONG TERM EFFECTS ON THE ENGINE. DEALERS SHOULD NOT ATTEMPT TO COMPARE ANY CUSTOMER VEHICLES EXHIBITING THIS NOISE WITH OTHER SIMILAR VEHICLES AS THE NOISE IS DIFFERENT FROM VEHICLE TO VEHICLE. MONITOR OASIS FOR UPDATES. 0896 - 2008 F250-550 SUPER-DUTY - 6.4L DIESEL - COOLANT LOSS DIAGNOSTICS SOME 2008 F250-550 SUPER-DUTY VEHICLES EQUIPPED WITH A 6.4L DIESEL ENGINE MAY EXHIBIT COOLANT EXPULSION FROM THE DEGAS BOTTLE. PRIOR TO MAKING ANY REPAIRS VERIFY THE COOLANT LEVEL IS NOT OVERFULL. THE COOLANT LEVEL SHOULD BE WITHIN THE COLD FILL RANGE ON THE DEGAS BOTTLE. IF NOT OVERFILLED AND STILL EXPELLING COOLANT PLEASE REVIEW UPDATED DIAGNOSTIC WORKSHOP MANUAL(WSM) PROCEDURES IN ENGINE COOLING SECTION 303-03. NOTE THAT SOME PRESSURE TEST EQUIPMENT MAY RESULT IN A FALSE LEAK INDICATION WHEN ATTACHED DIRECTLY TO THE DEGAS BOTTLE CAP. PRESSURE TESTING SHOULD ONLY BE CONDUCTED WITH THE CAP INSTALLED ON THE DEGAS BOTTLE, AS CLARIFIED IN THE UPDATED WSM. 0867 - HORN CONCERN FOR SOME 2001-2007 F-SD VEHICLES SOME 2001-2007 F-SD VEHICLES MAY HAVE A CONCERN WITH THE HORN AS A RESULT OF THE HORN SWITCH LOCATED WITHIN THE DRIVER AIR BAG MODULE. THE HORN SWITCH CAN NOW BE SERVICED SEPERATELY WITH SERVICE KIT P/N 6C3Z-13B802-B. REFER TO SECTION 413-06 OF THE ON-LINE WSM AND SSM 19926 FOR THE REPAIR PROCEDURES. IT IS NO LONGER NECESSARY TO REPLACE THE DRIVER AIR BAG MODULE ASSEMBLY TO RESOLVE HORN CONCERNS ON THESE VEHICLES. 0888 - 2008 E-SERIES ABS/RSC LIGHT ON CODES C1145, C1155, C1165 OR C1175 BUILT ON OR BEFORE 1/18/2008 SEE TSB 08-08-04 FOR DETAIL 0887 - 2008 E-SERIES - 6.0L VEHICLES BUILT 11/1/2007 THROUGH 1/15/2008 - RUNS ROUGH, MISS, STUMBLE/FLUTTER BETWEEN 1500-4000 RPM - BROKEN CRANKCASE-TO-HEAD TUBES SEE TSB 08-08-03 FOR DETAIL 0885 - 2004-2007 F-SUPER DUTY 650/F750 AND 2006-2007 LCF - NETS SOFTWARE ERROR CODE 99 SEE TSB 08-08-01 FOR DETAIL 0866 - SPARK PLUG REMOVAL INSTRUCTIONS 4.6L 3V / 5.4L 3V / 6.8L 3V SEE TSB 08-07-06 FOR DETAIL 0863 - SPARK PLUG PORCELAIN REMOVAL - ROTUNDA TOOL KIT 303-1398 - 4.6L 3V / 5.4L 3V/ 6.8L 3V ENGINES ROTUNDA TOOL KIT 303-1398 IS BEING SHIPPED TO DEALERS BEGINNING 3/26/2008. DEALERSHIPS SHOULD EXPECT TO RECEIVE THE KIT WITHIN THE NEXT 15-20 DAYS. THESE KITS WILL AID IN REMOVAL OF BROKEN SPARK PLUG PORCELAIN FROM 4.6L 3V/ 5.4L 3V / 6.8L 3V ENGINES. DETAILED TOOL KIT INSTRUCTIONS WILL BE PROVIDED IN A TECHNICAL SERVICE BULLETIN AVAILABLE BY 4/4/2008. ADDITIONALLY A NEW TECH TIME PLUS EPISODE PROVIDING AN OVERVIEW OF THE KIT WILL BE AVAILABLE AT FMCDEALER.COM NEAR FUTURE. 0857 - 2008 E-SERIES ABS/RSC LIGHT ON - CODES C1145, C1155, C1165 OR C1175 BUILT ON OR BEFORE 1/18/2008 SEE TSB 08-07-05 FOR DETAIL 0840 - 2008 F650/F750 CUMMINS ENGINES EQUIPPED WITH VERTICAL EXHAUST/LESS RAIN CAP. SOME 2008 F650/F750 VEHICLES CAN BE ORDERED WITH VERTICAL EXHAUSTS AND MAY BE ORDERED WITH AN EXHAUST RAIN CAP. NOTE THAT CUMMINS EQUIPPED VERTICAL EXHAUSTS ARE DESIGNED WITHOUT A RAIN CAP AND SHOULD NOT BE EQUIPPED/MODIFIED TO INCLUDE ONE. A DESIGN CHANGE IN THE VERTICAL STACK PIPE ON CUMMINS EQUIPPED VEHICLES REQUIRES NO RAIN CAP BE INSTALLED (AN ORDER GUIDE CORRECTION WILL BE MADE TO REFLECT THIS). WATER DRAINAGE IS PROVIDED BY DRAIN PORTS IN THE OUTLET SECTION OF THE EXHAUST AFTERTREATMENT SYSTEM. 0838 - 2007-2008 MULITPLE VEHICLES - SMART POWER DISTRIBUTION JUNCTION BOX (SPDJB) CIRCUIT FAULT DISABLE FEATURE THE SMART POWER DISTRIBUTION JUNCTION BOX (SPDJB) IN CERTAIN 2007-2008 VEHICLES HAVE BUILT-IN FUNCTIONALITY TO DISABLE CIRCUITS. IF A CIRCUIT FAULT IS DETECTED, A DTC FOR THE AFFECTED CIRCUIT WILL BE SET IN THE SPDJB AND THE CIRCUIT OUTPUT IS DISABLED UNTIL THE DTC(S) ARE CLEARED AND THE SPDJB PASSES A SELF TEST. IF ELECTRICAL SYMPTOMS ARE PRESENT, PERFORM A SELF-TEST ON THE SPDJB AND CHECK FOR DTC'S. FOLLOW NORMAL SHOP MANUAL DIAGNOSTICS TO ISOLATE AND REPAIR THE AFFECTED CIRCUIT(S). ONCE THE FAULT HAS BEEN REPAIRED, CLEARING THE DTC(S) AND PASSING A SELF-TEST OF THE SPDJB WILL RESTORE OUTPUT ON THE AFFECTED CIRCUIT. NOTE: REPLACEMENT OF THE SPDJB SHOULD NOT BE NECESSARY TO RESTORE FUNCTIONALITY AND SHOULD ONLY BE DONE IF DIRECTED TO DO SO BY SHOP MANUAL DIAGNOSTICS. 0835 - ANNOUNCING COMPLIANCE RECALL 08C01 DEMONSTRATION / DELIVERY HOLD COMPLIANCE RECALL 08C01: CERTAIN 2008 MODEL YEAR F-250 THROUGH F-550 SUPER DUTY VEHICLES EQUIPPED WITH DRIVER SEAT LUMBAR FRONT DRIVER SEAT BACK INSPECTION AND REPAIR. THIS FSA HAS BEEN POSTED TO FMCDEALER.COM. 0818 - 2006-2007 F-53 MOTORHOME - AXLE NOISE (DANA S110/S130) SOME 2006-2007 F-53 MOTORHOMES BUILT ON OR BEFORE 2/1/2007 MAY PRODUCE A WHINE/GROWL NOISE COMING FROM THE REAR AXLE ASSEMBLY. DIAGNOSE AXLE NOISE USING WORK SHOP MANUAL (WSM) SECTION 205-00. IF INSPECTION OF INTERNAL COMPONENTS REVEAL NO WEAR CONCERNS, INSPECT AND ADJUST BACK LASH OF RING AND PINION (0.006"-0.016"). IF NOISE PERSISTS AFTER BACK LASH ADJUSTMENT, REPLACEMENT OF RING AND PINION (W/BEARINGS) MAY BE NECESSARY AS REFERENCED IN WSM SECTION 205-00. IF RING AND PINION IS REQUIRED, DO NOT REPLACE DIFFERENTIAL CASE (CROSS SHAFT HALF ASSEMBLY) IF INSPECTION OF CASE REVEALS NO DAMAGE OR WEAR. 0812 - 2008 F-SUPER DUTY 6.4L DIESEL DIESEL PARTICULATE FILTER(DPF) REPLACEMENT SERVICE SUGGESTION. VEHICLES BUILT BEFORE 8/3/07. IF NORMAL PC/ED DIAGNOSTIC PROCEDURES LEAD TO REPLACEMENT OF THE DIESEL PARTICULATE FILTER(DPF) ON 2008 F250-550 SUPER-DUTIES BUILT PRIOR TO 8/3/07 AND EQUIPPED WITH 6.4L DIESEL ENGINE PLEASE ENSURE THAT THE ENGINE CONTROL MODULE(ECM) IS REPROGRAMMED TO THE LATEST SERVICE CALIBRATION IDENTIFIED IN TSB 07-17-3. WHEN REPROGRAMMING THE ECM ON AUTOMATIC TRANSMISSION EQUIPPED VEHICLES THE TRANSMISSION CONTROL MODULE(TCM) WILL ALSO AUTOMATICALLY BE REPROGRAMMED TO THE LATEST LEVEL. 0808 - 2006-2007 LCF - RATTLE UNDER CAB OVER BUMPS - BUILT ON OR BEFORE 12/3/2007 SEE TSB 08-06-05 FOR DETAIL 0805 - 2008 F-SUPER DUTY - DISTANCE TO EMPTY (DTE) NOT ACCURATE SOME 2008 F-SUPER DUTY VEHICLES MAY EXHIBIT A DISTANCE TO EMPTY (DTE) CALCULATION THAT IS PERCEIVED AS NOT BEING ACCURATE (READS EMPTY BUT TANK IS NOT EMPTY). DTE IS CALCULATED USING A RUNNING AVERAGE FUEL ECONOMY, WHICH IS BASED ON THE RECENT DRIVING HISTORY OF 500 MILES (800 KM). DTE CAN BE RE-INITIALIZED IF THE BATTERY IS DISCONNECTED. ENGINEERING IS CURRENTLY INVESTIGATING THE CONCERN, PLEASE DO NOT REPLACE THE INSTRUMENT CLUSTER, AS THIS WILL NOT RESOLVE THE ISSUE. PLEASE CONTINUE TO MONITOR OASIS FOR UPDATES. 0804 - 2008 F-SUPER DUTY 6.4L - P040D DTC WITH A LACK POWER OR LACK OF BOOST SOME 2008 F-SUPER DUTY 6.4L MAY EXHIBIT A P040D DTC WITH A LACK POWER OR LACK OF BOOST. 6.4L DIESELS HAVE (3) DIFFERENT SENSORS USED IN (5) DIFFERENT LOCATIONS WITH THE SAME BASE PART NUMBER 12B591. THESE SENSORS ARE NOT ALL INTERCHANGEABLE AND IT IS IMPORTANT TO ORDER THE CORRECT SENSOR FOR YOUR REPAIR IN ORDER TO AVOID CUSTOMER DISSATISFACTION WITH EXCESSIVE DOWNTIME. THE PCED PPT WA7 AND SERVICE PARTS CATALOG HAVE BEEN UPDATED TO CLARIFY DIAGNOSTICS AND PART SELECTION. 0802 - 2008 FOCUS / F-SUPER DUTY - SMART POWER DISTRIBUTION JUNCTION BOX (SPDJB) PROGRAMMING ERRORS SOME 2008 FOCUS OR F-SUPER DUTY VEHICLES MAY EXHIBIT POWER DOOR LOCKS INOP, INTERIOR DOME LAMP FLASHING, AND/OR DTC'S FOR NON-OPTIONAL EQUIPMENT AFTER SPDJB REPLACEMENT/REPROGRAMMING. THIS CAN HAPPEN BY NOT FOLLOWING THE WORKSHOP MANUAL PROCEDURES OR SELECTING THE INCORRECT VEHICLE EQUIPMENT OPTIONS WHEN FOLLOWING THE IDS 'PROGRAMMABLE MODULE INSTALLATION' PROCEDURE. THE RESULT IS AN INCORRECT CONFIGURATION FILE DOWNLOADED INTO THE SPDJB DURING THE 'PROGRAMMABLE MODULE INSTALLATION' PROCESS. VERIFY THE IDS IS AT SOFTWARE LEVEL B53.5 P10 OR HIGHER AS IT CONTAINS UPDATES TO SPDJB PROGRAMMING PROCEDURE. 0791 - 2008 LCF -CHECK ENGINE LIGHT ON - VARIOUS DTCS / LACK POWER - BUILT ON OR BEFORE 1/21/2008. SEE TSB 08-06-02 FOR DETAIL 0785 - 2008 F-SUPER DUTY - 6.4L - DTC P0528 AND/OR P0529 SEE TSB 08-05-14 FOR DETAIL 0780 - 2006-2007 Low Cab Forward - SPEAKERS INOPERATIVE - WATER LEAK INTO DOORS SEE TSB 08-05-11 FOR DETAIL 0778 - 2008 F-SUPER DUTY 6.4L - MIL, P0006B, P2563, P2263 WITH R WITHOUT A DRIVABILITY COMPLAINT. SOME 2008 F-SUPER DUTY EQUIPPED WITH A 6.4L DIESEL ENGINE MAY EXHIBIT ONE OR MORE OF THE FOLLOWING DURING COLD WEATHER OPERATING TEMPERATURES AT OR BELOWFREEZING 32F (0C): DIAGNOSTIC TROUBLE CODES(DTCS) P006B, P2563, AND OR P2263 ACCOMPANIED BY SURGE AT IDLE, SURGE AT TEADY STATE SPEED, LACK OF POWER ON ACCELERATION AND TURBOCHARGER OVERBOOST CONDITION. IF NORMAL PCED DIAGNOSTIC PROCEDURES DO NOTLEAD TO SENSOR AND/OR COMPONENT REPLACEMENT DO NOT ATTEMPT URTHER REPAIRS. ENGINEERING IS CURRENTLY INVESTIGATING. MONITOR ASIS FOR UPDATES. 0755 - 2008 F-SUPER DUTY F-450 - AXLE WHINE NOISE BETWEEN 50-60MPH (80-97 KM/H) - WIDE FRAME WITH PICKUP BOX - DANA S110 SEE TSB 08-05-03 FOR DETAIL 0501 - 2008 F-SUPER DUTY 6.4L - DIAGNOSTIC TROUBLE CODES (DTC) P0128 AND P0196 SOME 2008 F-SUPER DUTY VEHICLES EQUIPPED WITH A 6.4L DIESEL ENGINE MAY EXHIBIT DTC P0128 ENGINE COOLANT THERMOSTAT AND/OR P0196 ENGINE OIL TEMPERATURE SENSOR CIRCUIT. IF NORMAL DIAGNOSTIC PROCEDURES DO NOT RESOLVE VEHICLE CONCERN DO NOT ATTEMPT FURTHER REPAIRS. ENGINEERING IS CURRENTLY INVESTIGATING. MONITOR OASIS FOR UPDATES. 20228 1999-2008 7.3L/6.0L/6.4L/4.5L DIESEL - CLEAN THE CHARGE AIR COOLER (CAC) SYSTEM AFTER CERTAIN TURBO OR ENGINE FAILURES - SERVICE TIP ON A 7.3L, 6.0L, 6.4L, OR 4.5L DIESEL EQUIPPED VEHICLE IF THE TURBOCHARGER IS REPLACED FOR AN INTERNAL OIL LEAK OR COMPRESSOR SHAFT FAILURE, THE CHARGE AIR COOLER (CAC) SHOULD BE CHECKED FOR OIL CONTAMINATION AND CONSEQUENTLY CLEANED IF OIL CONTAMINATION IS FOUND. THE CAC SHOULD ALSO BE INSPECTED AND CLEANED OF OIL OR METAL CONTAMINATION AFTER AN ENGINE FAILURE THAT MAY HAVE PUSHED OIL/METAL INTO THE CAC DUE TO EXCESSIVE CRANKCASE PRESSURE. A THOROUGH CLEANING OF THE CAC SYSTEM IS NECESSARY TO PREVENT FURTHER DRIVABILITY OR ENGINE CONCERNS. EFFECTIVE DATE: 04/23/2008 20209 2008 F250-550 SUPER-DUTY 6.4L DIESEL - MESSAGE CENTER W/DTC P246C AND/OR P2463 SOME 2008 F250-550 SUPER-DUTY VEHICLES EQUIPPED WITH A 6.4L DIESEL ENGINE MAY EXHIBIT A CONTINUOUS DISPLAY OF DRIVE TO CLEAN IN THE INSTRUMENT CLUSTER MESSAGE CENTER WITH DIAGNOSTIC TROUBLE CODES(DTC) P246C: DPF RESTRICTION - FORCED LIMITED POWER AND/OR P2463: DPF RESTRICTION - SOOT ACCUMULATION. THIS

2007 Truck & Diesel SSMs 20072 2008 F-SUPER DUTY - "WIRING FAULT ON TRAILER" DISPLAYED IN MESSAGE CENTER WITH DTC C2806 SOME 2008 F-SUPER DUTY VEHICLES EQUIPPED W/ FACTORY TBC MAY HAVE "WIRING FAULT ON TRAILER" IN MESSAGE CENTER AND DTC C2806. C2806 IS SET WHEN A SHORT EXISTS BETWEEN ANY CIRCUIT AND THE OUTPUT LINE. TO AVOID REPEAT REPAIRS, 1)ALL CIRCUITS IN 7 PIN CONNECTOR BUNDLE (RIGHT/LEFT TURN, BACK UP, BRAKE, TAIL LAMP, ETC.) SHOULD BE ACTIVATED IN TURN, WHILE CHECK FOR VOLTAGE ON OUTPUT LINE IS BEING PERFORMED; 2)CHECK AFTERMARKET WIRING, ESPECIALLY ON 5TH WHEEL HITCHES. ALL WIRING MUST BE SOLDERED/SHRINK WRAPPED. USE OF SCOTCH LOCKS/OTHER CONNECTORS IS NOT RECOMMENDED; 3)CHECK FOR WATER INTRUSION IN C4099 AND ROUND 7-PIN CONNECTOR, REPLACEMENT IS NECESSARY FOR BOTH C4099 (PIGTAIL 3U2Z-14S411-JXA) AND THE ROUND 7 PIN CONNECTOR; ADD DIELECTRIC GREASE. IF NO WATER INTRUSION FOLLOW PINPOINT FOR C2806. EFFECTIVE DATE: 12/17/2007 20068 2008 F-SUPER DUTY 6.4L - DIAGNOSTIC TROUBLE CODES (DTC) P0128 AND P0196 SOME 2008 F-SUPER DUTY VEHICLES EQUIPPED WITH A 6.4L DIESEL ENGINE MAY EXHIBIT DTC P0128 ENGINE COOLANT THERMOSTAT AND/OR P0196 ENGINE OIL TEMPERATURE SENSOR CIRCUIT. IF NORMAL DIAGNOSTIC PROCEDURES DO NOT RESOLVE VEHICLE CONCERN DO NOT ATTEMPT FURTHER REPAIRS. ENGINEERING IS CURRENTLY INVESTIGATING. MONITOR OASIS FOR UPDATES. EFFECTIVE DATE: 12/13/2007 20067 2008 F-SUPER DUTY - 6.4L ENGINE VIBRATION AFTER A NEW COMPLETE ENGINE ASSEMBLY HAS BEEN REPLACED SOME 2008 F-SUPER DUTY VEHICLES WITH A DIESEL ENGINE MAY EXPERIENCE A VIBRATION AFTER A NEW COMPLETE ENGINE ASSEMBLY HAS BEEN INSTALLED. IF AN ENGINE VIBRATION OCCURS AFTER A NEW ENGINE HAS BEEN INSTALLED CHECK AND MAKE SURE THE FACTORY LIFTING BRACKET HAS BEEN REMOVED FROM THE RIGHT REAR OF THE ENGINE. FAILURE TO REMOVE THE BRACKET CAN CAUSE A VIBRATION AS IT GROUNDS OUT AGAINST THE BODY. EFFECTIVE DATE: 12/12/2007 20064 2004-2006 F-650/F-750 AND 2006 LCF - FUEL TANKS SOME 2004-2006 F-650/F-750 AND 2006 LCF TRUCKS WERE BUILT WITH STEEL FUEL TANKS. LATE 2006 MY VEHICLES HAD ALUMINIZED FUEL TANKS INSTALLED INTO THE F-650/F-750 AND LCF VEHICLE LINES, WHICH REPLACED THE PREVIOUS STEEL TANKS. ALL ALUMINIZED TANKS WILL HAVE A SUPPLIER BUILD DATE AFTER 10/2005 THAT IS STAMPED ON THE TANK (FORMAT MM-YY) POINTING TOWARD THE REAR OF THE VEHICLE. EFFECTIVE DATE: 12/04/2007 20020 2008 F-SUPER DUTY - 6.4L DIESEL EGR VALVE AND DPF FAILURES DUE TO HIGH SULFUR DIESEL FUEL SOME 2008 F250-550 6.4L DIESEL ENGINES MAY EXHIBIT DRIVABILITY AND/OR COMPONENT CONCERNS WITH EXHAUST GAS RECIRCULATION VALVES(EGRV) AND DIESEL PARTICULATE FILTERS(DPF) IF HIGH SULFUR DIESEL FUEL(GREATER THAN 500 PPM)IS USED. USE OF HIGH-SULFUR FUEL CAN CAUSE CORROSIVE DAMAGE TO THE EXHAUST GAS RECIRCULATION (EGR) AND DIESEL PARTICULATE FILTERS(DPF). USE ONLY ULTRA LOW SULFUR(15 PPM) NUMBER 1-D OR 2-D DIESEL FUEL IN YOUR 6.4L DIESEL ENGINE. THE ENGINE AND EXHAUST SYSTEM WERE DESIGNED TO ONLY USE THIS FUEL. USING HIGH SULFUR DIESEL FUEL IN A 6.4L DIESEL ENGINE DESIGNED TO USE ONLY ULTRA LOW SULFUR DIESEL FUEL MAY CAUSE CERTAIN EMISSION COMPONENTS TO MALFUNCTION WHICH MAY TURN ON THE SERVICE ENGINE SOON LIGHT INDICATING AN EMISSIONS-RELATED CONCERN. REFERENCE OWNER'S GUIDE AND DIESEL SUPPLEMENT FOR FURTHER INFORMATION. EFFECTIVE DATE: 10/26/2007 20001 SOME VEHICLES MAY EXPERIENCE A NO CRANK, NO START OR NO COMMUNICATION CONCERN AFTER REPROGRAMMING THE ECM, TCM, OR IC. REPROGRAMMING CONCERNS MAY BE CAUSED BY THE DLC OR VCM BECOMING DISCONNECTED, LOW BATTERIES ON THE IDS, OR THE IDS GOING INTO ANY TYPE OF SLEEP MODE. IF THERE WAS AN INTERRUPTION DURING REPROGRAMMING, MAKE SURE THE ORIGINAL IDS SESSION THAT WAS CREATED FOR THE VEHICLE IS NOT DELETED. IF THE ORIGINAL VEHICLE SESSION IS NOT USED OR DELETED BEFORE THE MODULES ARE COMPLETELY REPROGRAMMED, FURTHER REPROGRAMMING ERRORS CAN OCCUR. THE MODULE RECOVERY PROCEDURE IS NO LONGER AVAILABLE AND IT IS CRITICAL THAT MODULE SWAPPING IS NOT PERFORMED FROM VEHICLE TO VEHICLE. TO REGAIN COMMUNICATION WITH A MODULE THAT HAS BEEN ERASED DURING REPROGRAMMING, RESUME THE ORIGINAL SESSION ONCE THE IDS IS RE-BOOTED. EFFECTIVE DATE: 10/10/2007 19968 2008 F-SUPER DUTY 6.4L - INSPECTION TIPS FOR ENGINE AND EGR COOLER AFTER OVERHEAT OR SIGNIFICANT COOLANT LOSS. SOME 2008 F-SUPER DUTY 6.4L VEHICLES THAT HAVE EXPERIENCED EITHER OVERHEAT OR SIGNIFICANT LOSS OF COOLANT, PERFORM THE FOLLOWING INSPECTION: 1. REMOVE OIL FILTER AND INSPECT STAND PIPE. IF MELTED, ENSURE ENGINE IS NOT DAMAGED. REFER TO WSM SECTION 303-00:ENGINE SYSTEM-GENERAL INFORMATION INSPECTION AND VERIFICATION DIAGNOSIS AND TESTING. 2. REMOVE EXHAUST PRESSURE (EP) SENSOR AND TUBE FROM EGR-OC PIPE (WSM 303-14B). 3. INSTALL A PRESSURE TESTER INLINE WITH THE DEGAS BOTTLE HOSE USING ROTUNDA 014-R1068 ADAPTER AND PRESSURIZE TO RATING ON CAP. 4.INSPECT FOR COOLANT WHERE THE EP SENSOR WAS REMOVED. A GROSS EGR COOLER LEAK WILL PRODUCE COOLANT IMMEDIATELY, IT MAY TAKE 15 MINUTES FOR A SMALLER LEAK. IF COOLANT EMERGES, EGR COOLERS WILL NEED TO BE REMOVED AND TESTED OFF VEHICLE (WSM 303-08). CONTINUE WITH NORMAL DIAGNOSIS IF NO CONCERNS ARE FOUND. EFFECTIVE DATE: 09/18/2007 19952 2008 E-SERIES AND F-SERIES SUPER DUTY - TPMS LIGHT ONNO COMMUNICATION CONCERN SOME 2008 E-SERIES AND F-SERIES SUPER DUTY VEHICLES EQUIPPED WITH TIRE PRESSURE MONITORING SYSTEM (TPMS) WHEN DELIVERED MAY HAVE THE TPMS LIGHT ON. THE LIGHT IS ON BECAUSE THE TIRE PRESSURES ARE ALTERED DURING ASSEMBLY TO PREVENT TIRE FLAT SPOTTING AND TO ACCOMMODATE SHIPPING TO THE DEALER ON HAUL-AWAY CARRIERS. STEP B1 OF PDI WORKSHEET HAS THE TECHNICIAN ADJUST THE TIRE PRESSURES TO THE CORRECT PRESSURES FRONT AND REAR (THEY MAY BE DIFFERENT PSI FRONT AND REAR) ACCORDING TO PRESSURES CALLED-OUT ON THE DOOR JAM STICKER. WHEN THE VEHICLE IS DRIVEN AS PART OF THE PDI PROCESS, CORRECTLY PRESSURED TIRES WILL CAUSE THE TPMS LIGHT TO GO OUT. NOTE: REFERENCE PDI MANUAL SECTION B1 AND J4.E IDS IS RE-BOOTED. EFFECTIVE DATE: 09/12/2007 19950 VEHICLE EQUIPPED WITH VAPOR MANAGEMENT VALVE WITH A SERVICE PORT. SOME VEHICLES ARE EQUIPPED WITH A VMV (VAPOR MANAGEMENT VALVE)WITH AN INTEGRATED SERVICE PORT OR A REMOTE PORT. THE SERVICE PORT IS COVERED WITH A GREEN COLORED CAP THAT IS TETHERED TO THE VALVE. AFTER SERVICING FOR EVAP CONCERNS, BE SURE THE INSIDE OF THE CAP IS CLEAN,THE SEAL IS IN PLACE AND THE CAP RE-SECURED TO THE PORT. (FINGER TIGHTEN ONLY).THE CAP PROVIDES A SEAL FOR THE SERVICE PORT SCHRADER VALVE. EFFECTIVE DATE: 09/07/2007 19940 2008 F-SUPER DUTY - 6.4L NO EGR CONTROL DUE TO CIRCUIT ISSUES OF OTHER ENGINE CONTROL SENSORS SOME 2008 6.4L EQUIPPED F-SERIES TRUCKS WITH SENSOR CIRCUIT DTC'S P0193, P0642, P0643, P0108, P006B, P0107, P0472, P0473, AND P0101 RETRIEVED WITH EGR SYSTEM DTC'S P0404, P042F, OR P1335 MAY HAVE NO EGR VALVE MOVEMENT. THE LOSS OF EGR MOVEMENT FROM THE CIRCUIT FAULTS MAY HAVE INDUCED THE EGR SYSTEM CODES. CORRECT CIRCUIT SYSTEM DTC'S USING THE POWERTRAIN CONTROL EMISSION DIAGNOSIS (PCED) PRIOR TO DIAGNOSING THE EGR SYSTEM DTC'S. EFFECTIVE DATE: 08/31/2007 19938 2003-2008 MULTIPLE VEHICLES WITH A TORQSHIFT TRANSMISSION - INTERMITTENT CLUNK WHEN SHIFTING BETWEEN DRIVE, REVERSE AND PARK AND/OR DURING 2-3 UPSHIFT SOME 2003-2008 F-SUPER DUTY, 2003-2005 EXCURSION, 2004-2008 E-SERIES, 2006-2008 F53 MOTORHOME CHASSIS, AND 2006-2008 LOW CAB FORWARD VEHICLES EQUIPPED WITH A TORQSHIFT TRANSMISSION MAY EXHIBIT SOME OR ALL OF THE FOLLOWING CLUNK CONDITIONS: CLUNK WHEN SHIFTING FROM DRIVE OR REVERSE GEAR INTO PARK; CLUNK OR POP UPON INITIAL ENGAGEMENT FROM REVERSE TO DRIVE AT APPROXIMATELY 2-3 MPH (3-5 KM/H); CLUNK DURING 2-3 UPSHIFTS. VERIFY THAT THE CUSTOMER CONCERN FITS ONE OR MORE OF THESE CONDITIONS. THESE SPECIFIC CLUNK CONDITIONS MAY BE INTERMITTENT AND ARE A CHARACTERISTIC OF POWERTRAIN MECHANICAL LASH. DO NOT ATTEMPT REPAIR. EFFECTIVE DATE: 08/31/2007 19933 2006-2008 SUPER-DUTY / 2006-2008 ECONOLINE - DIESEL VEHICLE STORAGE RECOMMENDATIONS SOME 2006-2008 SUPER-DUTY AND 2006-2008 ECONOLINE VEHICLES WITH A 6.0L/6.4L DIESEL MAY EXHIBIT A RUNS ROUGH OR MISFIRE CONDITION DUE TO VALVE TRAIN DAMAGE FROM A STUCK VALVE OR VALVES. THIS CONDITION CAN OCCURS WHEN VEHICLES SIT WITHOUT BEING STARTED FOR LONG PERIODS OF TIME, AND GENERALLY OCCUR AT LOW MILEAGE. IT IS NOW RECOMMENDED TO 1. START THE ENGINE EVERY 15 DAYS AND MOVE THE VEHICLE AT LEAST 25 FEET. RUN IT AT FAST IDLE UNTIL IT REACHES NORMAL OPERATING TEMPERATURE. 2. SHIFT THE TRANSMISSION INTO ALL GEARS WHILE ENGINE IS RUNNING AT IDLE SPEED. THE NEW VEHICLE STORAGE POLICY IS CURRENTLY BEING UPDATE IN THE WARRANTY AND POLICY MANUAL WITH THIS INFORMATION. EFFECTIVE DATE: 08/24/2007 19926 SERVICE PROCEDURE UPDATE ANNOUNCEMENT - 2001-2007 F-SUPER DUTY - HORN SWITCH WHEN DIAGNOSING/REPAIRING HORN CONCERNS ON 2001-2007 F-SUPER DUTY VEHICLES, USE THE ONLINE VERSION OF THE WORKSHOP MANUAL. THE HORN REPAIR PROCEDURE HAS BEEN UPDATED IN SECTION 413-06. THERE IS NOW A SERVICE KIT AVAILABLE P/N 6C3Z-13B802-A. EFFECTIVE DATE: 08/20/2007 19905 2007-2008 EXPEDITION, 2008 F-SUPER DUTY, MARINER, EDGE, ESCAPE - CLUSTER/AUTOLAMPS DIMMING STRATEGYOR IC. INTERIOR BACKLIGHTING ON 2007-2008 EXPEDITION, 2008 F-SUPER DUTY, EDGE, ESCAPE, MARINER VEHICLES EQUIPPED WITH AUTOLAMP/SUNLOAD SENSOR WILL BEHAVE DIFFERENTLY WHEN HEADLAMPS ARE TURNED ON IN DAYTIME/DAWN/DUSK CONDITIONS. THE INFORMATION DISPLAY WILL APPEAR TO "FLICKER" IF VEHICLE ENTERS/EXITS LOWER AMBIENT LIGHT AREAS, I.E. TUNNELS/BRIDGES/SHADED AREAS. THIS IS A NORMAL CONDITION, DO NOT ATTEMPT REPAIR. TO VERIFY: 1)CONFIRM VEHICLE IS EQUIPPED W/ AUTOLAMP FEATURE; 2)PUT VEHICLE OUTSIDE IN BRIGHT SUNLIGHT AND TURN HEADLAMPS ON; 3)INFORMATION DISPLAY WILL NOT RESPOND TO ANY ADJUSTMENT OF DIMMER SWITCH; 4)COVER SUNLOAD SENSOR WITH LARGE OPAQUE OBJECT AND WAIT 60 SECONDS;5)ALL ILLUMINATED COMPONENTS INCLUDING INFORMATION DISPLAY WILL NOW DIM WHEN DIMMER SWITCH IS ADJUSTED UP OR DOWN. ALSO, REFER TO WORKSHOP MANUAL, SECTION 413-00, DESCRIPTION/OPERATION. EFFECTIVE DATE: 08/06/2007 19898 1997-2008 MULTIPLE VEHICLES - REAR LEAF SPRING NOISE NO COMMUNICATION CONCERN SOME 1997-2008 SUPER DUTY F-SERIES/RANGER, 1997-2007 F-150/E-SERIES, 97-01 EXPLORER/MOUNTIANEER, 01-05 EXPLORER SPORT TRAC, 06-07 MARK LT AND 2004 F-150 HERITAGE EQUIPPED WITH REAR LEAF SPRINGS MAY EXHIBIT AN INTERMITTENT SPRING SQUEAK/CLUNK WHEN COLD, OR WHEN DRIVING OVER ROUGH ROADS. TO SERVICE: 1)LIFT REAR OF VEHICLE, UNLOADING THE LEAF SPRINGS; 2)PRY OPEN SPRING NEAR LEAF TIP LINER USING A NON-METALLIC WEDGE (RUBBER COATED PRY BAR, WOOD DOORSTOP-TYPE, ETC.); 3)APPLY A FILM OF MOTORCRAFT SILICONE BRAKE CALIPER GREASE XG-3-A TO SURFACE OF LEAF TIP LINER (DO NOT USE STANDARD GREASE); 4)REMOVE WEDGE; 5)REPEAT FOR REMAINING TIPS. IF NOISE IS NOT ELIMINATED, CONTINUE WITH NORMAL WORKSHOP MANUAL DIAGNOSTICS. NOTE: IT IS VERY IMPORTANT TO USE A NON-METALLIC WEDGE. IF A METALLIC WEDGE IS USED, CORROSION PROTECTION CAN BE DAMAGED. EFFECTIVE DATE: 08/02/2007 19890 2008 F-450 PICK UP - STEERING WANDER ON RUTTED ROADS DUE TO THE STIFF COMMERICAL TIRES USED ON 2008 F-450 PICK UP, SOME CUSTOMERS MAY PERCEIVE A WANDER FEEL ON RUTTED/ROUGH ROADS. THE CONDITION MAY BE WORSE WITH TRACTION TIRES. TIRE CHANGES ARE NOT RECOMMENDED. FIRST, COMPARE TO THE SAME VEHICLE (F-450 PU ONLY). THE F-450 PU IS BASED ON THE F-450 CHASSIS CAB WITH SIGNIFICANT RIDE IMPROVEMENTS. STEERING WILL BE BETTER THAN THE F-450 CHASSIS CAB, BUT WILL NOT EQUAL THE STEERING OF A F-350 DRW. IF AFTER COMPARING TO ANOTHER F-450 PU, AND WANDER CONCERN STILL EXISTS, PROCEED WITH NORMAL DIAGNOSTICS PER THE WORKSHOP MANUAL, SECTION 211-00: STEERING SYSTEM GENERAL INFORMATION, DIAGNOSIS AND TESTING. EFFECTIVE DATE: 07/26/2007 19817 2008 F-SUPER DUTY - SOFT OR INCREASED BRAKE PEDAL TRAVEL - PERFORM BOTH MASTER CYLINDER BYPASS TEST & PINPOINT TEST F ON SOME 2008 F-SUPER DUTY VEHICLES WITH A CUSTOMER COMPLIANT OF SOFT BRAKE PEDAL FEEL OR INCREASED BRAKE PEDAL TRAVEL - PERFORM BOTH THE BRAKE MASTER CYLINDER BYPASS CONDITION TEST IN SECTION 206-00 AND PINPOINT TEST F IN SECTION 206-09 OF THE ON-LINE VERSION WORKSHOP MANUAL. DO NOT REPLACE ANY PARTS UNTIL AFTER COMPLETING BOTH TESTS. EFFECTIVE DATE: 06/13/2007 19815 2008 F-SUPER DUTY - 6.4L DIESEL ENGINE - THE FUEL COOLING PUMP NOISE SOME 2008 F-SUPER DUTY WITH 6.4L DIESEL ENGINE WITH THE FUEL COOLING PUMP (8B552), LOCATED ON DRIVER'S SIDE LOWER FAN SHROUD CAN PRODUCE A LOUD SQUEALING NOISE IF THE FUEL COOLING SYSTEM IS NOT COMPLETELY FILLED WITH COOLANT AND BLED OF AIR TRAPPED IN THE SYSTEM. BEFORE REPLACING THE PUMP OR PERFORMING OTHER REPAIRS, 1) MAKE SURE THAT ALL HOSE JOINTS ARE SECURE. 2) CHECK THE SYSTEM FOR LEAKS. 3) CHECK THE PRESSURE CAP FOR PROPER OPERATION. 4) MAKE SURE THAT THE SYSTEM IS COMPLETELY FILLED AND BLED; FOLLOWING THE PROCEDURES FOUND IN SECTION 303-04E OF THE 2008 F-SUPER DUTY WORKSHOP MANUAL. EFFECTIVE DATE: 06/13/2007 19814 2008 F-SUPER DUTY - ADDING KEY FOBS AND/OR KEYPAD ON VEHICLES NOT EQUIPPED WITH RKE FROM FACTORY IT IS NOT POSSIBLE TO ADD AND/OR PROGRAM KEY FOBS OR A KEYPAD TO WORK ON A 2008 F-SUPER DUTY THAT IS NOT EQUIPPED WITH REMORE KEYLESS ENTRY (RKE) FROM THE FACTORY. REPLACING THE SMART JUNCTION BOX (SJB) WILL NOT ENABLE THIS FUNCTION EITHER. ALSO, THE VEHICLE SECURITY KIT THAT IS AVAILABLE THROUGH FORD ACCESSORIES FOR 2008 SUPER DUTY CAN ONLY BE USED ON VEHICLES EQUIPPED WITH RKE FROM THE FACTORY. EFFECTIVE DATE: 06/13/2007 19774 2008 F-450 PICK UP - STEERING WANDER ON RUTTED ROADS SOME 2008 F-450 PICK UP TRUCKS MAY EXHIBIT A WANDER FEEL ON RUTTED/ROUGH ROADS DUE TO STIFF COMMERCIAL TIRES. THE CONDITION MAY BE WORSE WITH TRACTION TIRES. 1) SET TIRES TO PLACARD PRESSURE (NOT SIDEWALL). 2) VERIFY CONCERN WITH CUSTOMER, PAY ATTENTION TO ROAD CONDITION (SMOOTH VS. RUTTED/ROUGH). 3) COMPARE TO A LIKE F-450 PU (PREFERRED) OR CHASSIS CAB. 4) INSPECT CHASSIS COMPONENTS AND VERIFY FASTENER TORQUES. 5) VERIFY ALIGNMENT (INCLUDING REAR THRUST ANGLE). 6) ALSO SUGGEST THAT THE CUSTOMER ACCUMULATES AT LEAST 1000 MILES AS STEERING GEAR HAS A BREAK-IN PERIOD. TIRE CHANGES ARE NOT RECOMMENDED. THE F-450 PU IS BASED ON THE F-450 CHASSIS CAB WITH SIGNIFICANT RIDE IMPROVEMENTS. STEERING SHOULD BE BETTER THAN THE CHASSIS CAB, BUT MIGHT NOT EQUAL THE STEERING OF THE F-350 DRW. EFFECTIVE DATE: 05/23/2007 19751 2008 F-SUPER DUTY INCOMPLETE VEHICLES - LED LIGHTING FOR PROPER FUNCTION OF LED LIGHTING INSTALLED BY FINAL STAGE MANUFACTURERS OF INCOMPLETE OR MODIFIED VEHICLES, THE LAMP-OUT INDICATION FEATURE OF THE SMART POWER DISTRIBUTION JUNCTION BOX (SPDJB OR SJB) MUST BE TURNED OFF. TO ACCOMPLISH THIS, SELECT "PROGRAMMABLE PARAMETERS" IN THE IDS TOOLBOX, SELECT "EXTERIOR LIGHTING", THEN SELECT "STOP AND TAIL LAMP OUTAGE CONFIGURATION", THEN SELECT "LAMP OUTAGE TURNED OFF". PERFORMANCE OF THIS SSM SHOULD ONLY BE DONE AT THE REQUEST OF A REGISTERED INTERMEDIATE OR FINAL STAGE MANUFACTURER. FMVSS 108/CMVSS 108 COMPLIANCE IS THE RESPONSIBILITY OF THE FINAL STAGE MANUFACTURER. NOTE: IDS MUST BE UPDATED TO THE B48.11 DATABASE. THIS IS CONSIDERED A CUSTOMER PREFERENCE AND IS NOT COVERED UNDER WARRANTY. EFFECTIVE DATE: 05/07/2007 19746 2008 F-SUPER DUTY - ADDITION / REMOVAL OF SINGLE / DUAL ALTERNATORS (SERVICE TIP) IF ADDING/REMOVING AN ALTERNATOR ON A 2008 F-SUPER DUTY: IF YOU WANT TO REMOVE AN ALTERNATOR FROM A DUAL ALTERNATOR SYSTEM OR ADD AN ALTERNATOR TO A SINGLE ALTERNATOR SYSTEM, THE VID BLOCK SHOULD BE UPDATED TO REFLECT THE CHANGE; IF ADDING A SECONDARY ALTERNATOR TO A SINGLE ALTERNATOR VEHICLE, THE SECONDARY ALTERNATOR FIELD IN THE VID BLOCK MUST BE CHANGED FROM 0 TO 120 AMPS; IF REMOVING A SECONDARY ALTERNATOR FROM A DUAL ALTERNATOR VEHICLE, THE SECONDARY ALTERNATOR FIELD IN THE VID BLOCK MUST BE CHANGED FROM 120 AMPS TO 0. USING IDS, SELECT TOOLBOX, MODULE PROGRAMMING, PROGRAMMABLE PARAMETERS, TIRE SIZE/AXLE RATIO, SECONDARY GENERATOR - (PCM) = NO SECONDARY ALTERNATOR, SELECT 120A SECONDARY ALTERNATOR, AND THEN PUSH "TICK". VERIFY AND/OR CLEAR ANY DTCS BEFORE RELEASING VEHICLE TO CUSTOMER. EFFECTIVE DATE: 05/02/2007 19729 2008 F-SUPER DUTY - PARTS AVAILABLE FOR DEALER INSTALLATION OF TOWCOMMAND SYSTEM TO INSTALL A TRAILER BRAKE CONTROLLER ON A 2008 F-SUPER DUTY THAT WAS NOT ORIGINALLY EQUIPPED FROM THE FACTORY, ORDER 8C3Z-2140-D FOR VACUUM BOOST APPLICATIONS OR 7C3Z-2140-H FOR HYDROBOOST APPLICATIONS, A TBC MODULE, AND AN IP BIN. THE INSTUMENT CLUSTER MUST ALSO BE PROGRAMMED USING IDS. REFERENCE SECTION 206-10 OF THE WORKSHOP MANUAL FOR ADDITIONAL INFORMATION IF NEEDED. EFFECTIVE DATE: 04/24/2007 19670 2008 F-SUPER DUTY - 6.4L DIESEL ENGINE - ENGINE OIL LEAK SOME 2008 F-SUPER DUTY WITH A 6.4L DIESEL ENGINE BUILT PRIOR TO INDIANAPOLIS ESN-7008584 AND HUNTSVILLE ESN-0436024, MAY EXHIBIT AN OIL LEAK DUE TO A MISSING / ROLLED OR CUT OIL LEVEL INDICATOR TUBE O-RING. THIS LEAK MAY APPEAR TO BE THE REAR MAIN CRANKSHAFT SEAL, BEDPLATE SEAL OR OIL PAN. CAREFULLY CLEAN EXCESS SURFACE OIL AND CONFIRM LEAK LOCATION. EFFECTIVE DATE: 03/16/2007 19661 2003-2008 F-SUPER DUTY/2003-2005 EXCURSION/2004-2006 E-SERIES 350/450 - 6.0L/6.4L DIESEL - FIRST FIT(FF) MARKING ON HFCM FUEL FILTER - SERVICE TIP STARTING WITH MAY 2006 PRODUCTION, VEHICLES EQUIPPED WITH 6.0L OR 6.4L DIESEL ENGINES HAVE THE HORIZONTAL FUEL CONDITIONING MODULE(HFCM) FILTERS MARKED "FF" ON THE FILTER ENDCAP. THIS IS AN INDICATION THE FILTER IS A FIRST FIT. FIRST FIT FILTERS ARE EITHER THE ORIGINAL FILTER FROM PRODUCTION AT THE ASSEMBLY PLANT, OR FROM WHEN THE HFCM IS REPLACED AS A COMPLETE ASSEMBLY IN SERVICE ON PRIOR MODEL YEAR 6.0L VEHICLES. FUEL FILTERS SHOULD BE CHANGED EVERY 15,000 MILES OR SOONER, DEPENDING ON USAGE AND FUEL QUALITY. EFFECTIVE DATE: 03/09/2007 19639 1994-2008 MULTIPLE VEHICLES - DIESEL ENGINES USING CJ-4 OIL AND LOW SULFUR DIESEL FUEL - NEEDS MORE FREQUENT OIL CHANGE INTERVAL ON ALL MODEL YEAR DIESELS, OIL CHANGE INTERVALS NEED TO BE REDUCED BY HALF WHEN USING CJ-4 OIL AND LOW SULFUR DIESEL FUEL (500 PPM SULFUR MAXIMUM), OR ANY DIESEL FUEL CONTAINING GREATER THAN 15 PPM SULFUR. WHEN CJ-4 OIL AND FUELS CONTAINING GREATER THAN 15 PPM SULFUR ARE USED, THE OIL DEGRADES AT A FASTER RATE DUE TO INCREASED ACID LEVELS REQUIRING A SHORTENED OIL CHANGE INTERVAL. EFFECTIVE DATE: 03/01/2007 19637 2004-2008 MULTIPLE VEHICLES - CIGAR LIGHTER / POWER POINT FUSE REPLACEMENTS CUSTOMERS SHOULD BE ADVISED THAT ANY AFTER MARKET DEVICE PLUGGED INTO THE CIGAR LIGHTER / POWER POINT THAT CREATES AN OVER CURRENT CONDITION EXCEEDING THE 12VDC (180W/20A) RATING AND CAUSING THE 20A FUSE TO BLOW, IS NOT COVERED UNDER THE VEHICLE WARRANTY. POWER POINT / CIGAR LIGHTER SOCKETS HAVE A LOAD CAPACITY NOT TO EXCEED 12VDC/180W (20AMP). REPAIRS ARE NOT REIMBURSABLE UNDER WARRANTY IF 1) CUSTOMER USE OF THE POWER POINT(S) / CIGAR LIGHTER EXCEEDS THE 12VDC/180W (20AMP) RATING OF THE CIRCUIT AND CAUSES THE FUSE TO BLOW AS DESIGNED. 2) ALTERATION OR MODIFICATION OF THE VEHICLE'S ELECTRICAL SYSTEM AFTER THE VEHICLE LEAVES FORD'S CONTROL. FUSE REPLACEMENT DUE TO OVERLOADING OF THE CIRCUIT BY THECUSTOMER IS NOT A WARRANTABLE REPAIR. EFFECTIVE DATE: 02/23/2007 19635 1994-2008 - MULTIPLE VEHICLES - BIO-DIESEL FUEL USAGE SOME F-SUPER DUTY, E-SERIES, EXCURSION, LCF, AND F-650/750 VEHICLES WITH A DIESEL ENGINE, MAY EXHIBIT ENGINE OR FUEL SYSTEM CONCERNS WHEN USING FUEL WITH GREATER THAN 5% BIO-DIESEL CONCENTRATION. IN CURRENTLY DESIGNED VEHICLES, ONLY FUELS CONTAINING NO MORE THAN 5% BIO-DIESEL (B5) MAY BE USED IN FORD DIESEL POWERED VEHICLES, AS PUBLISHED IN THE DIESEL SUPPLEMENT OWNER GUIDE. IF NOT PROPERLY FORMULATED, HIGHER LEVELS OF BIO-DIESEL ARE PRONE TO: DEGRADE MORE QUICKLY THAN DIESEL FUEL, ATTACK VARIOUS METALS, AND HAVE INCREASED WATER CONTENT; WHICH LEAD TO CORROSION, HIGHER ENGINE DEPOSITS, DAMAGED SEALS, AND DAMAGED COMPOSITE MATERIALS IN THE FUEL SYSTEM. IT IS ALSO MORE LIKELY TO GEL AT COLD TEMPS THAN CONVENTIONAL DIESEL FUELS. EFFECTIVE DATE: 02/22/2007 19629 1999-2008 MULTIPLE VEHICLES - DIESEL ENGINE FUEL CONDITIONER SOME 1999-2008 F-SUPER DUTY, E-SERIES, EXCURSION, F650/750, AND LCF VEHICLES EQUIPPED WITH A DIESEL ENGINE MAY EXHIBIT LOW POWER, POOR FUEL ECONOMY, FUEL GELLING IN COLD WEATHER (A HIGHER OCCURRENCE OF FUEL GELLING MAY OCCUR WITH THE USE OF BIO-DIESEL BLENDED FUELS), EXCESSIVE WHITE SMOKE ON COLD START, HARD START, OR COKING OF COMPONENTS EXPOSED TO EXHAUST. THESE CONDITIONS MAY BE DUE TO POOR FUEL QUALITY. IF NO ROOT CAUSE IS FOUND DURING NORMAL DIAGNOSTICS, ADVISE THE CUSTOMER TO USE A DIFFERENT BRAND OF FUEL. USE OF A NON ALCOHOL ADDITIVE CAN IMPROVE CETANE LEVELS, SUCH AS "DIESEL CETANE BOOST AND PERFORMANCE IMPROVER" MOTORCRAFT PM-22-A (PM-22-B CAN). COLD FLOW PERFORMANCE CAN BE IMPROVED WITH "DIESEL FUEL ANTI-GEL AND PERFORMANCE IMPROVER" MOTORCRAFT PM-23-A (PM-23-B CAN). HAVE THE CUSTOMER MONITOR PERFORMANCE AFTER AT LEAST ONE BOTTLE. EFFECTIVE DATE: 02/21/2007 19619 2003-2007 MULTIPLE VEHICLES - MISFIRE, LACK OF POWER, BUCK/JERK, EXCESSIVE SMOKE, CRANK/NO START - 6.0L ENGINE - DIAGNOSTICS FOR FUEL SYSTEM THE PCED HAS BEEN UPDATED TO ASSIST IN DIAGNOSING THE POTENTIAL CAUSE OF FUEL SYSTEM RELATED CONCERNS SUCH AS MISFIRE, LACK OF POWER, BUCK/JERK, EXCESSIVE SMOKE OR CRANK/NO STARTS ON 6.0L EQUIPPED VEHICLES. THE FOLLOWING SECTIONS HAVE BEEN UPDATED WITH NEW TESTS AND INFORMATION: ELECTRIC FUEL PUMP PRESSURE TEST IN THE PERFORMANCE DIAGNOSTIC SUBROUTINES, COMBUSTION GAS IN THE FUEL RAIL BALLOON TEST IN SECTION 4 HARD START/NO START AND PERFORMANCE DIAGNOSTIC SUBROUTINES, PINPOINT TEST P, AND A POWER BALANCE TEST FOR IDENTIFYING FAULTY HIGH PRESSURE OIL CHECK VALVES IN PCED SECTION 4. EFFECTIVE DATE: 02/15/2007 19614 2003-2008 F-SUPERDUTY 6.0L/6.4L/2003-2005 EXCURSION 6.0L/2006-2007 LOW CAB FORWARD 4.5L-DIESEL - AIR FILTER WATER INGESTION/SNOW PACKING/P0103/165/149/MAF SOME 2003-2008 F-SUPER DUTY, 2003-2005 EXCURSION & 2006-2007 LCF VEHICLES EQUIPPED WITH A 4.5L/6.0L/6.4L DIESEL ENGINE MAY EXHIBIT A LACK OF POWER AND/OR A P0103 CODE (165,149 LCF). THIS MAY BE DUE TO THE INGESTION OF WATER/SNOW IN THE AIR INDUCTION SYSTEM SOAKING THE AIR FILTER ELEMENT. IF THE AMOUNT OF WATER INTRODUCED IN THE SYSTEM IS GREATER THAN THE CAPACITY OF AIR FILTER ELEMENT AND CONDENSATION CONTACTS THE MAF, A P0103 CODE WILL BE SET. AT THE EARLIEST OPPORTUNITY, OPEN THE HOOD AND CLEAR ALL THE SNOW/ICE FROM THE AIR FILTER HOUSING INLET (DO NOT REMOVE THE AIR FILTER) AND RESET THE AIR FILTER RESTRICTION GAUGE. IF THE FILTER IS ONLY WET IT WILL DRY AFTER ABOUT 15 ± 30 MINUTES OF DRIVING AT HIGHWAY SPEEDS. AT THE EARLIEST OPPORTUNITY, OPEN THE HOOD AND RESET THE AIR FILTER RESTRICTION GAUGE. EFFECTIVE DATE: 02/14/2007 19602 2006-2007 MUILTPLE VEHICLES - NAVIGATION SYSTEM DVD INSTALLATION SOME 2006-2007 VEHICLES EQUIPPED WITH A NAVIGATION SYSTEM MAY HAVE A SOFTWARE LEVEL MISMATCH DURING INITIAL DVD SYSTEM DISK INSTALLATION. WHEN THE SYSTEM DVD IS LOADED, THE FOLLOWING MESSAGE MAY BE SEEN: "!WARNING! YOU HAVE SELECTED TO INSTALL AN OLDER VERSION OF THE NAVIGATION DVD. INSTALLING THE DISC COULD RESULT IN DATA LOSS." THIS IS A RESULT OF DVD VERSION LEVEL NOT MATCHING SOFTWARE VERSION OF THE NAVIGATION RADIO DUE TO RUNNING CHANGES. IF THIS IS THE INITIAL INSTALLATION, PRESS "CONTINUE" AND LOAD DVD AS NORMAL. IT WILL NOT EFFECT SYSTEM OPERATION. DVDS CONTINUE TO BE UPDATED. UPDATES FROM ORIGINAL DISK THAT CAME WITH VEHICLE ARE AVAILABLE FOR PURCHASE THROUGH NORMAL PARTS SYSTEM AT CUSTOMER'S EXPENSE. EFFECTIVE DATE: 02/05/2007 19584 2007 MULTIPLE VEHICLES - "NO VIDEO" DISPLAYED ON DVD SCREEN SOME 2007 VEHICLES WITH DELPHI FAMILY ENTERTAINMENT SYSTEM MAY EXPERIENCE AUDIO WITH NO VIDEO DISPLAYED. THIS COULD BE A RESULT OF THE FOLLOWING CONDITIONS: 1) WHILE PLAYING A VIDEO THE FES WAS TURNED OFF AND THE AUDIO IS SOURCED TO DVD AUX BUTTON ON THE RADIO OR MEDIA BUTTON ON THE FES. 2) THE FES IS PLAYING A DVD AND THE FES VIDEO BUTTON WAS PRESSED ONCE OR TWICE. TO VERIFY THE FES ISN'T IN ONE OF THESE MODES, FOLLOW THESE STEPS. 1) TURN ON THE FES USING THE POWER BUTTON, IF THE VIDEO SCREEN STILL DOESN'T DISPLAY, PROCEED TO STEP 2. 2) PRESS THE FES VIDEO BUTTON ONCE OR TWICE, IF THE VIDEO STILL DOESN'T DISPLAY SUSPECT A FAULTY FES UNIT. EFFECTIVE DATE: 01/23/2007 9998 - COPYRIGHT 2007 FORD MOTOR COMPANY. ALL RIGHTS RESERVED.

2006 & Older Truck & Diesel SSMs 19950 VEHICLE EQUIPPED WITH VAPOR MANAGEMENT VALVE WITH A SERVICE PORT. SOME VEHICLES ARE EQUIPPED WITH A VMV (VAPOR MANAGEMENT VALVE)WITH AN INTEGRATED SERVICE PORT OR A REMOTE PORT. THE SERVICE PORT IS COVERED WITH A GREEN COLORED CAP THAT IS TETHERED TO THE VALVE. AFTER SERVICING FOR EVAP CONCERNS, BE SURE THE INSIDE OF THE CAP IS CLEAN,THE SEAL IS IN PLACE AND THE CAP RE-SECURED TO THE PORT. (FINGER TIGHTEN ONLY).THE CAP PROVIDES A SEAL FOR THE SERVICE PORT SCHRADER VALVE. EFFECTIVE DATE: 09/07/2007 19532 2004-2007 F-650/750 - TURN SIGNALS FLASHING RAPIDLY AFTER MODIFICATION - SERVICE TIP MOST 2004-2007 F-650/750 VEHICLES ARE PRODUCED WITH STANDARD TURN SIGNAL BULBS. IF A BODY BUILDER INSTALLS LIGHT EMITTING DIODE (LED) LAMPS, THE TURN SIGNALS MAY FLASH RAPIDLY WHEN TURNED ON. TO SERVICE, REPLACE THE FACTORY INSTALLED FLASHER WITH A YC3Z-13350-AA FLASHER. THIS MODIFICATION IS NOT COVERED BY WARRANTY, BUT WILL RESOLVE THE CONCERN. EFFECTIVE DATE: 12/15/2006 19518 2003-2007 F-SUPER DUTY / 2003-2005 EXCURSION / 2004-2007 E-SERIES - 6.0L - NEW IDS EGR TOOL / NO START - 6.0L ENGINE - DIAGNOSTICS FOR FUEL SYSTEM A NEW EGR SYSTEM DIAGNOSTIC TOOL HAS BEEN DEVELOPED AND IS AVAILABLE ON IDS VERSION 46.7 P6 AND IS LOCATED UNDER POWERTRAIN ; AIR MANAGEMENT SYSTEM ; EGR SYSTEM TEST. THIS TOOL MAY BE USED WITH 6.0L DIESEL EQUIPPED VEHICLES TO DIAGNOSE THE FOLLOWING CONDITIONS: LACK OF POWER, ROUGH IDLE, BLACK SMOKE, WHITE SMOKE, HESITATION, SURGE, P0401, P0402, P0404, P0470, P0478, P2262, P2263, P1335, P0299. IN ADDITION, ONLINE PC/ED DIAGNOSTICS HAVE BEEN UPDATED TO INCLUDE THE NEW TOOL PROCEDURES.PID READING IS A PERCENT OF TANK FULL, SO 50% SHOULD EFFECTIVE DATE: 12/11/2006 19487 2003-2007 F-SUPER DUTY/2004-2007 E-SERIES/2003-2005 EXCURSION 6.0L - NO CRANK P1705/P0706/P0707 - DIAGNOSE AND SERVICE THE COOLING FAN SOME VEHICLES EQUIPPED WITH A 6.0L DIT AND TORQSHIFT TRANSMISSION MAY EXHIBIT A NO CRANK/NO START. DTC'S P1705, P0706, P0707 MAY BE PRESENT. IF LOW VOLTAGE (3-4 VOLTS) IS FOUND AT THE TRANSMISSION RANGE POSITION SENSOR PIN 21 CIRCUIT 371 (CIRCUIT 1929 E-SERIES), ELECTRICALLY DISCONNECT THE COOLING FAN CLUTCH AND RETEST THE VOLTAGE. IF THE VOLTAGE NOW READS 12 VOLTS AND THE VEHICLE CRANKS AND STARTS, VERIFY WITH A SHORT TEST DRIVE THAT CODES DO NOT RETURN. DO NOT SERVICE THE TRANSMISSION OR REPLACE THE TRANSMISSION RANGE POSITION SENSOR FOR THIS CONDITION. REFER TO THE APPROPRIATE WIRING DIAGRAM AND WORKSHOP MANUAL SECTION TO DIAGNOSE AND SERVICE THE COOLING FAN. EFFECTIVE DATE: 11/15/2006 19484 1999-2007 7.3L/6.0L/4.5L DIESEL - CLEAN THE CHARGE AIR COOLER (CAC) SYSTEM AFTER CERTAIN TURBO OR ENGINE FAILURES - SERVICE TIP ON A 7.3L, 6.0L, OR 4.5L DIESEL EQUIPPED VEHICLE IF THE TURBOCHARGER IS REPLACED FOR AN INTERNAL OIL LEAK OR COMPRESSOR SHAFT FAILURE, THE CHARGE AIR COOLER (CAC) SHOULD BE CHECKED FOR OIL CONTAMINATION AND CONSEQUENTLY CLEANED IF OIL CONTAMINATION IS FOUND. THE CAC SHOULD ALSO BE INSPECTED AND CLEANED OF OIL OR METAL CONTAMINATION AFTER AN ENGINE FAILURE THAT MAY HAVE PUSHED OIL/METAL INTO THE CAC DUE TO EXCESSIVE CRANKCASE PRESSURE. A THOROUGH CLEANING OF THE CAC SYSTEM IS NECESSARY TO PREVENT FURTHER DRIVABILITY OR ENGINE CONCERNS. EFFECTIVE DATE: 11/14/2006 19420 2003-2007 MULTIPLE VEHICLES 6.0L - DAMAGED/MISSIN OIL FILTER STANDPIPE DUE TO OVERHEATING SOME 2003-2007 6.0L ENGINE EQUIPPED VEHICLES MAY EXHIBIT A CRANK NO-START AS A RESULT OF ENGINE OVERHEATING. BEFORE ATTEMPTING ANY REPAIR EXAMINE THE OIL FILTER STAND PIPE FOR SIGNS THAT IT IS DAMAGED OR MISSING. IF THE STAND PIPE IS DAMAGED/MISSING, PERFORM NORMAL WORKSHOP MANUAL DIAGNOSTICS TO ISOLATE THE CAUSE OF THE OVERHEAT. ONCE THE ROOT CAUSE OF THE OVERHEAT IS FOUND, PERFORM BASE ENGINE DIAGNOSTICS TO ISOLATE IF ANY OTHER ENGINE DAMAGE HAS OCCURRED. THE OIL FILTER STANDPIPE WILL BE DAMAGED WHEN TEMPERATURE'S EXCEED 350 DEGREES FAHRENHEIT. WITH THESE TEMPERATURES BASE ENGINE OR HIGH PRESSURE OIL SYSTEM DAMAGE CAN OCCUR. EFFECTIVE DATE: 10/09/2006 19418 2003-2007 MULTIPLE VEHICLES - ENTERTAINMENT SYSTEM - INOPERATIVE HEADPHONES AND REMOTES - SERVICE TIP SOME 2003-2007 VEHICLES EQUIPPED WITH ENTERTAINMENT SYSTEMS MAY EXPERIENCE INOPERATIVE HEADPHONES AND/OR REMOTES. IT'S VERY IMPORTANT TO TEST THE BATTERIES THAT OPERATE THESE DEVICES AND CONFIRM THEY ARE GOOD BEFORE REPLACING THE SUSPECTED COMPONENT. CONTINUE TO MONITOR OASIS FOR FUTURE UPDATES. PLEASE NOTE: REAR SEAT ENTERTAINMENT COMPONENTS (INCLUDING HEADPHONES, REMOTE ETC) THAT FAIL BECAUSE OF CUSTOMER ABUSE OR NEGLECT, ARE NOT WARRANTABLE. EFFECTIVE DATE: 10/06/2006 19417 2003-2007 F-SUPER DUTY/2003-2005 EXCURSION 6.0L - WATCH FOR OIL FLOW FROM THE BASE ENGINE OIL PUMP SOME 2003-2007 F-SUPER DUTY AND 2003-2005 EXCURSION VEHICLES EQUIPPED WITH A 6.0L DIESEL MAY EXHIBIT LOW BASE ENGINE OIL PRESSURE CAUSED BY A LEAK IN THE HIGH PRESSURE OIL SYSTEM. IF A HIGH PRESSURE SYSTEM LEAK IS SEVERE, THE HIGH PRESSURE PUMP MAY USE A LARGER VOLUME OF OIL THAN THE BASE ENGINE (GEROTOR) PUMP CAN PRODUCE WHILE CRANKING. IF BASE ENGINE OIL PRESSURE IS LOW, REMOVE OIL FILTER, HOLD DOWN THE OIL DRAIN VALVE (LEFT SIDE OF HOUSING) WITH A SCREWDRIVER AND CRANK THE ENGINE WHILE WATCHING FOR OIL FLOW FROM THE BASE ENGINE OIL PUMP. IF FLOW IS PRESENT, USE THE UPDATED DIAGNOSTICS FOR THE HIGH PRESSURE OIL SYSTEM (ELECTRONIC VERSION OF PC/ED, SECTION 4, STEP 10E). IF THERE IS NO FLOW AT THE OIL FILTER HOUSING DIAGNOSE THE BASE ENGINE OIL SYSTEM FIRST (WORKSHOP MANUAL SECTION 303-01C). EFFECTIVE DATE: 10/06/2006 19389 2003-2007 MULTIPLE VEHICLES 6.0L DIESEL - NO START CONDITION WITH LOW INJECTION CONTROL PRESSURE (ICP) - SERVICE TIPE - DIAGNOSTICS FOR FUEL SYSTEM SOME AFTERMARKET OIL FILTERS ARE OF THE INCORRECT SIZE AND FIT FOR 6.0L DIESEL EQUIPPED VEHICLES. THIS MAY CAUSE OIL FLOW RESTRICTIONS OR DRAIN BACK, AND MAY RESULT IN A CRANK NO START/HARD START CONDITION WITH LOW OR SLOW TO BUILD INJECTION CONTROL PRESSURE(ICP). WHEN PERFORMING NORMAL DIAGNOSTICS, INSPECT THE OIL FILTER FOR CORRECT FIT AND APPLICATION. INSPECT FOR DAMAGE TO THE OIL FILTER STAND PIPE, CHECK VALVE, AND OIL FILTER HOUSING LID. INSTALL A FILTER THAT FITS PROPERLY, SUCH AS A MOTORCRAFT FL-2016.BRAND OF FUEL. USE OF A NON ALCOHOL EFFECTIVE DATE: 09/27/2006 19360 2005-2007 F-SUPER DUTY - INSTALLATION OF UPFITTER SWITCHES ON TRUCKS NOT ORIGINALLY EQUIPPED FROM THE FACTORY TO INSTALL THE UPFITTER SWITCHES ON A 2005-2007 F-SUPER DUTY, THAT WAS NOT ORIGINALLY EQUIPPED FROM THE FACTORY, ORDER 5C3Z-14A303-AA (WIRE ASY), 5C3Z- 13D730-AAA (SWITCH ASY), AND 5C3Z-2513546-CAA (BOX - UTILITY - LESS HOUSING). THE WIRING HARNESS BOLTS ON, AND THE SWITCH PLUGS INTO IT. THE UTILITY BOX IS ONLY NEEDED IF THE TRUCK IS NOT EQUIPPED WITH A TRAILER BRAKE CONTROLLER. IT MAY BE NECESSARY TO REMOVE THE INSTRUMENT PANEL TO INSTALL THE HARNESS FROM THE BULKHEAD SIDE. REFERENCE Q-117 WHICH CAN BE FOUND AT HTTPS://WWW.FLEET.FORD.COM/TRUCKBBAS/TOPICS/QVMP.HTML FOR ADDITIONAL INFORMATION IF NEEDED. EFFECTIVE DATE: 09/08/2006 19353 2005-2007 F-SUPER DUTY - UPFITTER SWITCH 2005-2007 F-SUPER DUTY VEHICLES MAY BE EQUIPPED WITH UPFITTER SWITCHES (ACCESSORY SWITCHES) LOCATED ON THE INSTRUMENT PANEL BELOW THE CLIMATE CONTROLS. THIS OPTION INCLUDES FOUR LOW CURRENT ON/OFF SWITCHES THAT CONTROL TWO 10-AMP AND TWO 30-AMP FUSED RELAYS. THE SWITCHES ARE DESIGNED TO ALLOW THE CUSTOMER TO MANUALLY CLOSE A RELAY TO PROVIDE POWER TO ACCESSORIES. REFERENCE Q-117 WHICH CAN BE FOUND AT: HTTPS://WWW.FLEET.FORD.COM/TRUCKBBAS/TOPICS/QVMP.HTML FOR ADDITIONAL INFORMATION IF NEEDED. EFFECTIVE DATE: 09/06/2006 19335 1999-2007 MULTIPLE VEHICLES - HYDRAULIC BRAKES - GEL-LIKE SUBSTANCE FLOATING ON TOP OF FLUID IN MASTER CYLINDER - SERVICE TIP SOME 1999 F-800, 1999-2007 F-SUPER DUTY, MOTORHOME CHASSIS, 2000-2005 EXCURSION, 2000-2007 F-650/750, AND 2006-2007 LCF VEHICLES MAY EXHIBIT A CLEAR GEL-LIKE SUBSTANCE IN THE HYDRAULIC BRAKE MASTER CYLINDER RESERVOIR. THIS SUBSTANCE IS A SILICONE BASE LUBRICANT USED DURING ASSEMBLY OF THE MASTER CYLINDER. IT WILL FLOAT ON TOP OF THE BRAKE HYDRAULIC FLUID IN THE MASTER CYLINDER. ADVISE THE CUSTOMER THAT THIS CONDITION IS CONSIDERED NORMAL AND IN NO WAY AFFECTS THE OPERATION OF THE BRAKE SYSTEM. IT DOES NOT REQUIRE ANY SERVICE ACTION. EFFECTIVE DATE: 08/30/2006 19257 1999-2007 F-SUPER DUTY - FUEL GAUGE/CLUSTER FAILURES CAUSED BY WELDING - SERVICE TIP ON 1999-2007 F-SUPER DUTY VEHICLES, BEFORE WELDING ON THE FRAME OR BODY OF A UNIT, DISCONNECT THE BATTERY, INSTRUMENT CLUSTER, ABS MODULE AND THE PCM. JUST DISCONNECTING A BATTERY CABLE IS NOT ENOUGH TO PREVENT DAMAGE TO THESE COMPONENTS. PLEASE REFER QVM BULLETIN Q18 AND Q123 AT HTTPS://WWW.FLEET.FORD.COM/TRUCKBBAS/TOPICS/QVMP.HTML FOR ADDITIONAL INFORMATION. EFFECTIVE DATE: 07/06/2006 19254 2005-2007 F-SUPER DUTY - KIT AVAILABLE FOR DEALER INSTALLATION OF TOWCOMMAND SYSTEM TO INSTALL A TRAILER BRAKE CONTROLLER ON A 2005-2007 F-SUPER DUTY THAT WAS NOT ORIGINALLY EQUIPPED FROM THE FACTORY, ORDER KIT 5C3Z-19H332-AA FOR ALL GAS ENGINE APPLICATIONS; OR ORDER KIT 5C3Z-19H332-BA FOR ALL DIESEL ENGINE APPLICATIONS. FOLLOW THE INSTALLATION PROCEDURES IN THE INSTRUCTION SHEET INCLUDED IN THE KIT. REFERENCE SECTION 206-10 OF THE WORKSHOP MANUAL FOR ADDITIONAL INFORMATION IF NEEDED. EFFECTIVE DATE: 06/30/2006 19251 2003-2007 F-SUPER DUTY/2003-2005 EXCURSION/2004-2006 E-SERIES 6.0L - PERCEIVED EXCESSIVE FAN NOISE SOME 6.0L EQUIPPED VEHICLES MAY HAVE PERCEIVED EXCESSIVE FAN NOISE. FAN SPEED, FAN NOISE AND FUEL CONSUMPTION ALL WILL INCREASE FROM DRIVING CONDITIONS THAT INCLUDE TRAILER TOWING, HILL CLIMBING, HEAVY LOADS, HIGH SPEED AND HIGH AMBIENT TEMPERATURE, INDIVIDUALLY OR IN COMBINATION. THE AMOUNT OF FAN NOISE INCREASES AND DECREASES AS ENGINE POWER REQUIREMENTS AND VEHICLE DRIVING CONDITIONS CHANGE AS THE VEHICLE IS DRIVEN. THIS IS TO BE EXPECTED, AND IS NORMAL TO THE OPERATION OF THE VEHICLE, AND SOMETIMES CAN BE MISTAKEN FOR TRANSMISSION DOWNSHIFTING OR SLIPPAGE, LACK OF POWER, OR OTHER ABNORMAL CONDITION, WHICH IT IS NOT. HIGH FAN NOISE MIGHT ALSO BE HEARD WHEN THE ENGINE IS FIRST STARTED, AND SHOULD NORMALLY DECREASE AFTER DRIVING FOR A SHORT TIME. EFFECTIVE DATE: 06/29/2006 19235 1996-2007 MULTIPLE VEHICLES - CK TIRE CIRCUMFERENCE & TIRE INFLATION SOME 4WD VEHICLES EQUIPPED WITH CONTROL TRAC/INTELLIGENT 4WD/ALL WHEEL DRIVE MAY EXHIBIT A SHUDDER ON ACCELERATION, NOISE FROM THE FRONT DRIVELINE AND/OR TRANSFER CASE, AXLE WINDUP AND/OR BINDING WHILE DRIVING AND BEING OPERATED IN THE 4X4/AUTO 4X4 MODE. OTHER 4X4 VEHICLES EQUIPPED WITH (MANUAL OR ELECTRONIC SHIFT) AND A 4X2 MODE MAY ALSO NOT SHIFT ON THE FLY TO 4X4 AUTO OR 4X4 HIGH AT HIGHWAY SPEEDS. THIS MAY BE DUE TO INCORRECT TIRE CIRCUMFERENCE OR IMPROPER TIRE INFLATION PRESSURES. FOUR WHEEL DRIVE AND ALL WHEEL DRIVE VEHICLES REQUIRE THAT ALL FOUR TIRES HAVE THE SAME CIRCUMFERENCE. VERIFY THAT ALL FOUR TIRES HAVE NO MORE THAN 1/4 INCH VARIATION IN CIRCUMFERENCE AND THAT THEY ARE INFLATED TO THE PROPER TIRE PRESSURES(S). EFFECTIVE DATE: 06/19/2006 19192 2003-2007 F-SUPER DUTY/2003-2005 EXCURSION - 6.0L - AIR INDUCTION SYSTEM APPEARS TO BE WARPED AND/OR NOT SEALING SOME 2003-2007 F-SUPER DUTY AND 2003-2005 EXCURSION VEHICLES WITH A 6.0L ENGINE MAY EXHIBIT AN AIR INDUCTION SYSTEM HOUSING THAT APPEARS TO BE WARPED AND/OR NOT SEALING. THE ENGINE SIDE OF THE HOUSING THAT CLAMPS TO THE AIR FILTER HAS A SEAL THAT REQUIRES A HIGH INSERTION FORCE. THIS MAY RESULT IN A WARPED, OR NOT FULLY SEATED, APPEARANCE. GAPS BETWEEN THE HOUSING AND THE FILTER CAN BE AS LARGE AS 0.94 INCHES (24MM) AND STILL MAINTAIN A SEAL. DO NOT REPLACE ANY AIR INDUCTION SYSTEM PARTS IF THERE IS A GAP OF 0.63 INCHES (16MM) OR LESS. IF THE GAP IS GREATER THAN 0.63 INCHES, REMOVE THE FILTER AND REINSTALL. IF THE GAP IS STILL GREATER THAN 0.63 INCHES AFTER RESEATING THE HOUSING TO THE FILTER, REPLACE THE AIR FILTER ELEMENT ONLY. EFFECTIVE DATE: 05/18/2006 19159 2003-2006 F-SUPER DUTY/2004-2006 E-SERIES/2003-2005 EXCURSION 6.0L - EGR VALVE APPLICATION THERE ARE TWO DIFFERENT EGR VALVES USED ON 2003-2006 VEHICLES EQUIPPED WITH A 6.0L ENGINE BASED ON VEHICLE BUILD DATE. THE EGR VALVE RETURN SPRING PRELOAD IS DIFFERENT BETWEEN THE TWO EGR VALVES, SO EVEN THOUGH THEY LOOK SIMILAR EXTERNALLY, MAKE SURE THE CORRECT VALVE IS BEING INSTALLED FOR THE VEHICLE YOU ARE CURRENTLY SERVICING. THE PCM CALIBRATION FOR THE VEHICLES USING EACH TYPE OF VALVE IS DIFFERENT, TO ACCOMMODATE THE HIGHER RETURN SPRING PRELOAD. FAILURE TO INSTALL THE CORRECT EGR VALVE CAN CAUSE INCORRECT EGR VALVE POSITION (EGRVP), WHICH MAY LEAD TO REPEAT EGR CODES, SURGING, BUCKING, EXCESSIVE SMOKE AND OTHER ENGINE RELATED DRIVEABILITY SYMPTOMS. THE PART CATALOG DOES CORRECTLY IDENTIFY THE CORRECT EGR VALVE TO USE BY BUILD DATE. EFFECTIVE DATE: 04/05/2006 19099 2003-2006 F-SUPER DUTY/2003-2005 EXCURSION/2004-2006 E-SERIES - 6.0L - P0404 SERVICE TIP SOME 2003-2006 F-SUPER DUTY, 2003-2005 EXCURSION, AND 2004-2006 E-SERIES VEHICLES EQUIPPED WITH A 6.0L DIESEL ENGINE MAY SET A P0404 DTC IF THE BATTERY IS DISCONNECTED, KAM IS RESET, THE EGR VALVE IS REPLACED, OR IF THE EGR VALVE IS REMOVED AND REINSTALLED. PERFORM THE WDS/IDS KOEO ON DEMAND SELF TEST TO LEARN EGR VALVE CLOSED POSITION IF ANY OF THE LISTED CONDITIONS EXIST. EFFECTIVE DATE: 02/22/2006 19098 MULTIPLE VEHICLES - SULFUR BUILD-UP ON FUEL LEVEL SENSOR - ADD "CHEVRON TECHRON PLUS FUEL SYSTEM CLEANER" TO FUEL AND FILL WITH FRESH FUEL GASOLINE OR DIESEL VEHICLES MAY EXHIBIT ERRATIC FUEL GAUGE READINGS, ILLUMINATED MIL, AND DTC P0463, P2068 AND/OR B1202, B2627 MAY BE PRESENT. THIS CONDITION MAY OCCUR DUE TO SULFUR CONTAMINATION FOUND IN SOME LOCAL FUELS WHICH MAY CAUSE TEMPORARY CONTAMINATION OF THE FUEL SENDER CARD. BEFORE REPLACING ANY COMPONENT, CLEAR DTC'S, DRAIN FUEL TANK (IF FACILITIES PERMIT), ADD TECHRON CONCENTRATE PLUS FUEL SYSTEM CLEANER AND ADVISE CUSTOMER TO USE AN ALTERNATE BRAND OF FUEL. THE CONDITION SHOULD CORRECT ITSELF IN A FEW MILES. ADVISE CUSTOMERS TO UTILIZE THE TRIP ODOMETER TO MONITOR FUEL CONSUMPTION. REPLACEMENT OF COMPONENTS OR PCM REPROGRAMMING MAY NOT FIX THE CONCERN. IF CONCERN PERSISTS PERFORM NORMAL DIAGNOSIS AND REPAIR. OBTAIN THE NEW TECHRON PLUS FUEL ADDITIVE LOCALLY FROM YOUR LOCAL AUTOMOTIVE CHEMICAL SUPPLY SOURCE OR AUTO PARTS STORE. EFFECTIVE DATE: 02/22/2006 19017 MULTIPLE VEHICLES - HO2S AND CATALYST MONITOR SENSORS - SERVICE TIP HO2S SENSORS(HEGO)AND DOWNSTREAM CATALYST MONITOR SENSORS (CMS) ARE NOT THE CAUSE OF DTCS P0171,P0172,P0174,P0175, P0420,OR P0430. DO NOT REPLACE THE HO2S SENSORS OR MONITORS FOR THESE CODES UNLESS VERIFIED THROUGH PINPOINT DIAGNOSTIC TESTS FOR OTHER EXISTING DTCS, AS OUTLINED IN THE PC/ED SERVICE MANUAL. WHEN THE CATALYST OR ANY EXHAUST COMPONENT REPLACEMENT IS NECESSARY, USE CARE AS TO NOT PHYSICALLY DAMAGE ANY SENSORS ATTACHED TO THE SYSTEM. EFFECTIVE DATE: 01/23/2006 18994 2005-2006 F-SUPER DUTY AND 2005 EXCURSION - BLOCK HEATER CORD MISSING THE BLOCK HEATER FOR THE 6.0L ENGINE IS NOW OPTIONAL ON 2005-2006 F-SUPER DUTY AND 2005 EXCURSION VEHICLES (ORDER CODE 41H). THE BLOCK HEATER IS STILL STANDARD IF VEHICLES ARE ORDERED IN CANADA, OR IN THE STATES OF AK, CO, IA, ME, MN, MT, ND, SD, WI, AND WY. ALL 6.0L ENGINES WILL HAVE THE HEATER ELEMENT INSTALLED IN THE ENGINE, THE ATTACHING CORD IS THE OPTIONAL COMPONENT. IF EQUIPPED, THE CORD IS STOWED IN THE FRONT BUMPER OPENING. DO NOT INSTALL BLOCK HEATER CORDS UNDER WARRANTY. IF THE CORD IS MISSING, AND THE VEHICLE WAS ORDERED IN CANADA, ONE OF THE STATES ABOVE, OR WITH ORDER CODE 41H, A MISBUILT UNIT CLAIM SHOULD BE FILED. EFFECTIVE DATE: 12/21/2005 18926 2005 EXCURSION/2005-2006 E-SERIES/F-SUPER DUTY - 6.0L - NO ICP FROM INJECTOR SEAL/SPRING CLIP SOME 2005 EXCURSION AND 2005-2006 F-SUPER DUTY, AND E-SERIES VEHICLES EQUIPPED WITH A 6.0L DIESEL MAY EXHIBIT A HARD START, OR NO START CONDITION WITH LOW OR NO INJECTION CONTROL PRESSURE (ICP). DURING NORMAL HIGH PRESSURE SYSTEM DIAGNOSIS, BE SURE TO INSPECT WHERE THE HIGH PRESSURE OIL RAIL SEATS INTO THE TOP OF EACH FUEL INJECTOR FOR A DAMAGED OR MISSING SEAL RING AND/OR SPRING CLIP. IF COMPONENTS ARE MISSING, THEY MUST BE LOCATED OR ENGINE DAMAGE WILL RESULT. THE MOST LIKELY LOCATIONS ARE IN THE TOP OF THE HEAD, IN THE OIL PAN, OR IN THE PICK UP SCREEN. IF THE COMPONENTS ARE NOT FOUND, INSPECT THE LOW PRESSURE OIL PUMP AND REGULATOR. EFFECTIVE DATE: 11/07/2005 18778 MULTIPLE VEHICLES - ENGINE INSTALLATION INSTRUCTIONS WHEN REPAIRING A VEHICLE USING A FORD REMANUFACTURED (FR) OR MOTORCRAFT LONG BLOCK OR SHORT BLOCK, PLEASE REVIEW AND FOLLOW THE ENGINE INSTALLATION INSTRUCTIONS THAT COME WITH EACH LONG OR SHORT BLOCK. FOLLOWING THESE INSTRUCTIONS WILL HELP PREVENT REPEAT REPAIRS AND ENSURE CUSTOMER SATISFACTION. EFFECTIVE DATE: 08/12/2005 18578 2003-2005 MULTIPLE VEHICLES - DTC P0191, P0171 AND/OR P0174 FOR 2003-2005 MULTIPLE VEHICLE LINES WHICH USE ELECTRONIC RETURNLESS FUEL SYSTEM {ERFS}, THE APPEARANCE OF SELF TEST CONTINUOUS MEMORY DIAGNOSTIC TROUBLE CODE P0191 (FRP CKT PERFORMANCE) DOES NOT SPECIFICALLY INDICATE A FUEL RAIL PRESSURE SENSOR OR FUEL SYSTEM CIRCUIT FAILURE. THE FUEL RAIL SENSOR SHOULD NOT BE REPLACED BASED ONLY UPON THE APPEARANCE OF THIS DTC ALONE. FOLLOW THE REVISED ON-LINE PC/ED PINPOINT TESTING FOR DTC P0191 TO DIAGNOSE. ALSO, THE APPEARANCE OF DTC'S P0171 (HO2S11 LEAN PRT THRT) AND/OR P0174 (HO2S21 LEAN PRT THRT) MAY BE THE RESULT OF LOW FUEL PRESSURE. DO NOT REPLACE ANY COMPONENTS OR REPROGRAM THE PCM UNLESS PINPOINT TESTING OR OTHER PUBLISHED SERVICE PROCEDURES SPECIFICALLY PROVIDES THAT REPAIR ACTION. EFFECTIVE DATE: 04/25/2005 18503 2003-2005 F-SUPER DUTY/EXCURSION AND 2004-2005 E-SERIES - 6.0L INJECTOR REPLACEMENT - SERVICE TIP ON ALL 6.0L DIESEL ENGINES ANYTIME AN INJECTOR IS LOOSENED, REMOVED, OR REPLACED, THE COPPER WASHER AND INJECTOR O-RINGS MUST BE REPLACED. WHEN REPLACING AN INJECTOR, MAKE SURE THE OLD COPPER WASHER HAS BEEN REMOVED FROM THE INJECTOR CUP. EFFECTIVE DATE: 03/23/2005 18465 1997-2005 MULTIPLE VEHICLES - INTERMITTENT MIL ON WITH DTC P0460 - SERVICE TIP SOME 1997-2005 VEHICLES MAY EXHIBIT AN INTERMITTENT MALFUNCTION INDICATOR LAMP (MIL) ON WITH DTC P0460 (FUEL LEVEL SENSOR CIRCUIT MALFUNCTION). THIS CONDITION MAY BE CAUSED BY AN IMPROPERLY INSTALLED REMOTE START SYSTEM, AFFECTING THE FLUID LEVEL INPUT (FLI) INFORMATION TO THE PCM. THE CONDITION MAY BE DIFFICULT TO DUPLICATE. TO SERVICE, CHECK FOR AN IMPROPERLY INSTALLED FORD OR AFTERMARKET REMOTE STARTER SYSTEM. THE INSTRUMENT CLUSTER OR HEC MUST HAVE POWER TO ALL 'HOT IN RUN' CIRCUITS FOR THE FUEL GAUGE CIRCUIT TO PROPERLY RELAY FLI INFORMATION TO THE PCM (EITHER BY NETWORK COMMUNICATION OR A DIRECT HARDWIRE CIRCUIT). EFFECTIVE DATE: 03/11/2005 18217 MULTIPLE VEHICLES - FUEL LEVEL INDICATION CONCERNS - SERVICE TIPK, EXCESSIVE SOME 2000-2005 SUPER DUTY F-SERIES/F-150/EXCURSION/EXPEDITION/NAVIGATOR, 2001-2005 ESCAPE, 2002-2003 BLACKWOOD, 2002-2005 EXPLORER 4DR/MOUNTAINEER, AND 2003-2005 AVIATOR VEHICLES MAY EXHIBIT FUEL LEVEL INDICATOR CONCERNS. PRIOR TO STARTING NORMAL DIAGNOSTICS, PERFORM THE FOLLOWING QUICK TEST: 1) DISCONNECT THE BATTERY(S) FOR ONE MINUTE AND RECONNECT. 2) USE THE NGS DIAGNOSTIC (RED) CARD TO VIEW THE 'FUELLVL PID' IN THE HEC/ICM TO CHECK THE FUEL SIGNAL TO THE INSTRUMENT CLUSTER. THE PID READING IS A PERCENT OF TANK FULL, SO 50% SHOULD HAVE A FUEL GAUGE INDICATION OF ABOUT 1/2 TANK. THE PID VALUE RESPONDS INSTANTLY TO FUEL SLOSH AND VEHICLE TILT, BUT THE FUEL GAUGE RESPONDS MORE SLOWLY TO COMPENSATE FOR SLOSH. IF AN ISSUE IS CONFIRMED, PROCEED WITH NORMAL DIAGNOSTICS FOR THE SENDER OR CLUSTER BASED ON THE RESULTS.AT LEAST ONE BOTTLE. EFFECTIVE DATE: 10/08/2004 18107 1994-2003 MULTIPLE VEHICLES WITH 7.3L DIT - INJECTOR PERFORMANCE TEST PROCEDURE THERE IS A NEW PROCEDURE AVAILABLE FOR TESTING INJECTORS ON ALL 7.3L DI TURBO EQUIPPED VEHICLES. A NEW 7.3L DIESEL FUEL INJECTOR TEST STAND, TOOL NUMBER 310-141, HAS BEEN SHIPPED TO ALL FORD DEALERSHIPS. INSTRUCTIONS FOR USING THIS TOOL ARE IN ELECTRONIC VERSIONS OF THE 2001-2003 PC/ED MANUAL (JULY 2004 OR LATER), SECTION 4A. THE TOOL WILL DIAGNOSE INTERNAL INJECTOR SEALING FAILURES, BUT NOT INJECTOR CONCERNS CAUSED BY CONTAMINATION FROM FUEL QUALITY OR LACK OF OIL MAINTENANCE. INJECTOR REMOVAL IS REQUIRED SO ALL OTHER INJECTOR ELECTRICAL AND BASE ENGINE DIAGNOSIS MUST BE PERFORMED PRIOR TO TESTING WITH THE NEW TOOL. REFER TO APPROPRIATE MY PC/ED FOR ALL INITIAL DIAGNOSIS. IF AN INJECTOR IS SUSPECTED AFTER INITIAL DIAGNOSIS, REFER TO A 2001-2003 PC/ED FOR THE TOOL USAGE PROCEDURE. EFFECTIVE DATE: 08/30/2004 17810 - 1998-2004 CROWN VICTORIA/GRAND MARQUIS/TOWN CAR - TRANSMISSION FAILURE AND REPAIR - SERVICE TIP SOME 1998-2004 CROWN VICTORIA, GRAND MARQUIS AND TOWN CAR VEHICLES MAY EXHIBIT A TRANSMISSION FAILURE WHERE THERE IS A LARGE AMOUNT OF METAL OR DEBRIS IN THE PAN. WHEN THE TRANSMISSION IS REPAIRED OR REPLACED PERFORM THE FOLLOWING TO AVOID REPEAT REPAIRS: -FLUSH ALL TRANS LINES USING THE PROCEDURE OUTLINED IN SECTION 307-01 OF THE WORKSHOP MANUAL. -REPLACE THE OIL TO AIR (OTA) COOLER (IF EQUIPPED) AS IT CANNOT BE FLUSHED. -INSTALL AN IN LINE-FILTER KIT (XC3Z-7B155-CA) TO CATCH ANY EXTRA DEBRIS THAT MAY HAVE REMAINED IN THE LINES AFTER FLUSHING. -ALWAYS REPLACE THE TRANSMISSION FLUID FILTER. 17683 - 2003-2004 SUPER DUTY F-SERIES/EXCURSION AND 2004 ECONOLINE 6.0L - ENGINE OIL LEAKS AT LOWER CRANKCASE SOME 2003-2004 SUPER DUTY F-SERIES/EXCURSION AND 2004 ECONOLINE VEHICLES WITH A 6.0L ENGINE MAY EXHIBIT AN OIL LEAK THAT APPEARS TO BE COMING FROM THE LOWER CRANKCASE (BED PLATE). CLEAN THE SUSPECT AREA AND ADD DYE TO DETERMINE LEAK SOURCE. INSPECT FOR CAM AND/OR CRANK SENSOR O-RING LEAKAGE THAT RESULTS IN OIL TRAVEL GIVING THE APPEARANCE OF A LOWER CRANKCASE LEAK. CAM AND CRANK SENSOR O-RINGS ARE AVAILABLE FOR SERVICE (CMP: 3C3Z-9N693-HA [OUTER] 3C3Z- 9N693-JA [iNNER] / CPK: 3C3Z-9C064-DA). LOWER CRANKCASE LEAKS CAN BE CAUSED BY REMOVAL OF THE FRONT OR REAR COVER WITHOUT CUTTING THE "T" JOINT AREAS. WHEN SERVICING THE FRONT COVER APPLY A BEAD OF RTV SEALANT AT THE CRANKCASE TO LOWER CRANKCASE SEAM. WHEN SERVICING THE REAR ENGINE COVER APPLY A BEAD OF SEALANT AT THE CRANKCASE TO LOWER CRANKCASE SEAM AND THE OIL PUMP COVER JOINT. EFFECTIVE DATE: 04/01/2004 supercedes to 3c3z-9229-b for cmp rins 17643 - 2003-2004 SUPER DUTY F-SERIES/EXCURSION WITH TORQSHIFT - HARSH/SLIPPING ENGAGEMENTS, UPSHIFTS AND/OR DOWNSHIFTS - ADAPTIVE SHIFT STRATEGY WHEN THE BATTERY IS DISCONNECTED ON 2003-2004 SUPER DUTY F-SERIES AND EXCURSION VEHICLES WITH A TORQSHIFT TRANSMISSION, THE ADAPTIVE SHIFT STRATEGY MAY BE LOST, TEMPORARILY RESULTING IN HARSH/SLIPPING ENGAGEMENTS, UPSHIFTS AND/OR DOWNSHIFTS. THIS CONDITION IS NORMAL AND MAY ALSO OCCUR ON NEW VEHICLES THAT HAVE JUST ARRIVED FROM THE PLANT. TO ACCELERATE ADAPTIVE LEARNING: WARM ENGINE AND TRANSMISSION TO NORMAL OPERATING TEMPERATURE; PERFORM 3 SERIES OF UPSHIFTS AT LIGHT, MEDIUM, AND HEAVY THROTTLE; PERFORM 3 SETS OF ENGAGEMENTS (N-R, N-D, D-R, AND R-D) WITH FOOT FIRMLY ON BRAKE, WAITING 3 SECONDS BETWEEN EACH EVENT; THIS PROCEDURE IS TO BE PERFORMED TWO TIMES, ONCE WITH AND ONCE WITHOUT TOW/HAUL ACTIVATED. 17605 - 6.0 Liter overheats with plow- 2003-2004 SUPER DUTY F-SERIES 6.0L - ENGINE OVERHEATING WITH SNOW PLOW INSTALLED SOME 2003-2004 SUPER DUTY F-SERIES EQUIPPED WITH A 6.0L DIESEL AND SNOW PLOW PACKAGE (86M) MAY EXHIBIT THE ENGINE OVERHEATING DURING NORMAL HIGHWAY DRIVING DUE TO THE SNOW PLOW BLADE DISRUPTING AIRFLOW, CAUSING THE ENGINE COOLING FAN TO STOP TURNING OR SPIN IN REVERSE. INSTALL REVISED CLUTCH FAN 4C3Z-8A616-SA (ONLY FOR SNOW PLOW APPLICATIONS). SEE WORKSHOP MANUAL SECTION 303-03 FOR REMOVAL AND INSTALLATION. NOTE: INSTALLATION OF THIS COMPONENT MAY RESULT IN REDUCED FUEL ECONOMY. NOTE: PRIOR TO THE AVAILABILITY OF THE REVISED CLUTCH FAN, A JUMPER MAY HAVE BEEN INSTALLED BETWEEN THE FAN CONNECTOR ON THE RADIATOR SHROUD AND ITS NORMAL CONNECTION TO THE ENGINE HARNESS, ALLOWING THE FAN TO OPERATE CONTINUOUSLY. THIS JUMPER MUST BE REMOVED AND DISCARDED TO RETURN FAN OPERATION TO NORMAL AND PREVENT POSSIBLE DTC P0480 FROM OCCURRING. 17573 - 1994-2004 VARIOUS VEHICLES EQUIPPED WITH 6.0L/7.3L - INJECTION CONTROL PRESSURE (ICP) AND EXHAUST BACK PRESSURE (EBP) WIRING CONNECTOR SERVICE KIT SOME 1994-2004 VEHICLES EQUIPPED WITH A 7.3L OR 6.0L DIESEL ENGINE MAY EXHIBIT DRIVEABILITY CONDITIONS CAUSED BY THE ICP AND EBP WIRING CONNECTORS. IF A POOR CONNECTION EXISTS, THE ENGINE CONTROL SYSTEM MAY ENTER A DEFAULT MODE AND SET EITHER DIAGNOSTIC TROUBLE CODE P1280 (7.3L ICP), P2285 (6.0L ICP) OR P0472 (6.0L AND 7.3L EBP). THESE DTC'S TYPICALLY IDENTIFY AN OPEN CIRCUIT. IF ANY OF THESE CODES IS PRESENT, CLEAR THE CODE AND WIGGLE TEST THE CONNECTOR. IF THE WIGGLE TEST DUPLICATES THE ISSUE, EITHER CONNECTOR MAY BE REPLACED WITH SERVICE KIT 3C3Z-12224-BA (1994-1996 7.3L) OR 3C3Z-12224-AA (1997-2003 7.3L AND 2003-2004 6.0L). THE KIT CONTAINS A CONNECTOR WITH PIGTAIL, 3 BUTT SPLICES, 3 SHRINK TUBES AND INSTRUCTIONS. 17571 1994-2004 MULTIPLE VEHICLES WITH 7.3L OR 6.0L - MIL ON WITH DTC P0603 OR P0605 SOME 1994-2004 SUPER DUTY F-SERIES, ECONOLINE AND 2000-2004 EXCURSION VEHICLES EQUIPPED WITH 7.3L OR 6.0L DIESEL ENGINES MAY EXHIBIT DIAGNOSTIC TROUBLE CODES P0603 (POWERTRAIN CONTROL MODULE KEEP ALIVE MEMORY ERROR) OR P0605 (POWERTRAIN CONTROL MODULE READ ONLY MEMORY ERROR). DTC P0603 MAY BE GENERATED IF THE PCM, OR BOTH BATTERIES, ARE DISCONNECTED. TO SERVICE DTC P0603 ON 7.3L EQUIPPED VEHICLES, FIRST RUN THE ENGINE FOR MORE THAN 30 SECONDS, THEN CLEAR ALL DTC'S. FOR 6.0L EQUIPPED VEHICLES, REPROGRAM THE PCM TO THE LATEST CALIBRATION LEVEL USING WDS RELEASE B28.9 OR HIGHER. TO SERVICE DTC P0605 ON EITHER 7.3L OR 6.0L EQUIPPED VEHICLES, REPROGRAM THE PCM TO THE LATEST CALIBRATION LEVEL USING WDS RELEASE B28.9 OR HIGHER. CALIBRATION UPDATES CAN ALSO BE OBTAINED AT www.MOTORCRAFT.COM.R PERFORMANCE AFTER AT LEAST ONE BOTTLE. EFFECTIVE DATE: 02/20/2004 17351 - 2003-2004 SUPER DUTY F-SERIES/EXCURSION WITH TORQSHIFT - HARSH DISENGAGEMENT WHEN SHIFTING FROM REVERSE TO PARK SOME 2003-2004 SUPER DUTY F-SERIES AND EXCURSION VEHICLES BUILT BEFORE 11/14/2003 WITH A 6.0L DIESEL ENGINE AND TORQSHIFT AUTOMATIC TRANSMISSION MAY EXHIBIT A HARSH DISENGAGEMENT WHEN SHIFTING FROM REVERSE TO PARK. A CLUNK MAY ALSO BE HEARD DURING THIS DISENGAGEMENT. TO CORRECT THIS CONDITION, REPLACE THE ORIGINAL SOLENOID BODY MANUAL VALVE WITH A REDESIGNED PART 4C3Z-7D376-AA. TO PERFORM THIS REPAIR, FIRST REMOVE THE SOLENOID BODY ASSEMBLY. REPLACE THE MANUAL VALVE WITH THE REDESIGNED VALVE, INSERTING IT PLUGGED-END FIRST INTO THE SOLENOID BODY. USE A NEW SOLENOID BODY-TO-CASE GASKET (3C3Z-7C155-DA) DURING REINSTALLATION, CLEAN AND REUSE THE BOTTOM PAN GASKET, AND TOP OFF WITH MERCON SP TRANSMISSION FLUID. 17339 1995-2004 OBDII EQUIPPED VEHICLES - DTC P0171 AND/OR P0174 SOME 1995-2004 OBDII EQUIPPED VEHICLES MAY EXHIBIT A MALFUNCTION INDICATOR LAMP (MIL) ON WITH DIAGNOSTIC TROUBLE CODE (DTC) P0171 (SYSTEM TOO LEAN - BANK 1) AND/OR P0174 (SYSTEM TOO LEAN - BANK 2) DUE TO A VACUUM LEAK IN THE PCV SYSTEM. TO SERVICE, INSPECT THE PCV SYSTEM INCLUDING ALL RUBBER COMPONENTS, ELBOW CONNECTORS AT INTAKE MANIFOLD PORTS AND THE PCV VALVE ITSELF FOR DETERIORATION OR CHAFING. SQUEEZING THE RUBBER COMPONENTS MAY REVEAL DETERIORATION AND CRACKS NEAR BRITTLE OR SOFT SPOTS. DETERIORATION MAY CAUSE HOSES TO COLLAPSE AND NOT RETURN TO THEIR NATURAL FORM. REPLACE ONLY THE AFFECTED PCV COMPONENTS. REPLACING THE PCM, MAF SENSOR OR HEGO(S) WILL NOT REPAIR LEAN CODES CAUSED BY LEAKING PCV COMPONENTS. EFFECTIVE DATE: 11/12/2003 17268 1994-2003 MULTIPLE VEHICLES WITH 7.3L DIT - IDLE ROLL/LOPE ON COLD START SOME 1994-2003 SUPER DUTY F-SERIES/E-SERIES AND 2000-2003 EXCURSIONS EQUIPPED WITH THE 7.3L DIT ENGINE MAY EXHIBIT AN IDLE ROLL/LOPE ON COLD START THAT LASTS UP TO ONE MINUTE. THIS CONDITION IS CONSIDERED A CHARACTERISTIC OF THE 7.3L. THE FOLLOWING STEPS CAN BE TAKEN BY THE CUSTOMER TO REDUCE THE LIKELIHOOD OF THIS CONDITION: CHANGE TO A 10W-30 OIL (XO-10W-30-QSD) LABELED CI-4 OR CH-4; PLUG IN THE BLOCK HEATER WHEN OUTSIDE TEMPERATURES ARE GOING TO BE BELOW 30F (-1C); LEAVE THE IGNITION IN THE RUN POSITION FOR A FULL 2 MINUTES SO THE GLOW PLUGS CAN FULLY HEAT THE CYLINDERS BEFORE CRANKING THE ENGINE. EFFECTIVE DATE: 10/13/2003 17076 - 2003-2004 SUPER DUTY/EXCURSION 6.0L - WATER IN FUEL LIGHT ILLUMINATED SOME 2003-2004 SUPER DUTY/EXCURSION VEHICLES EQUIPPED WITH A 6.0L POWERSTROKE MAY EXHIBIT A WATER IN FUEL (WIF) LIGHT ON, WHICH DOES NOT TURN OFF AFTER WATER HAS BEEN DRAINED FROM THE HORIZONTAL FUEL CONDITIONING MODULE (HFCM). THIS MAY BE DUE TO CORROSION/SEDIMENT BUILD UP IN THE WATER RESERVOIR. TO SERVICE, FIRST VERIFY ELECTRICAL CONNECTIONS. IF ELECTRICAL CONNECTIONS ARE OKAY, REMOVE THE FUEL MANIFOLD FROM THE HFCM. INSPECT/CLEAN DEBRIS (MAX 25 PSI AIR) FROM THE WATER RESERVOIR IN HFCM HOUSING. INSTALL NEW FUEL MANIFOLD PN 3C3Z-9B249-AB AND REASSEMBLE THE FUEL MANIFOLD TO THE HFCM. REFER TO WORKSHOP MANUAL SECTION 310-01 FOR HFCM DISASSEMBLY AND ASSEMBLY PROCEDURES. 16966 - ICP & EBP WIRING CONNECTOR SERVICE KIT 1994-2003 VARIOUS VEHICLES EQUIPPED WITH 6.0L/7.3L - INJECTION CONTROL PRESSURE (ICP) AND EXHAUST BACK PRESSURE (EBP) WIRING CONNECTOR SERVICE KIT, SOME 1994-2003 VEHICLES EQUIPPED WITH A 7.3L OR 2003 MY 6.0L DI TURBO ENGINE MAY EXHIBIT DRIVEABILITY CONDITIONS CAUSED BY THE ICP AND EBP WIRING CONNECTORS. IF A POOR CONNECTION EXISTS, THE ENGINE CONTROL SYSTEM MAY ENTER DEFAULT AND SET EITHER A P1280 (7.3L - ICP), P2285 (6.0L - ICP) OR A P0472 (6.0L AND 7.3L - EBP) DTC. THESE DTC'S TYPICALLY IDENTIFY AN OPEN CIRCUIT. IF EITHER OF THESE CODES IS PRESENT, CLEAR THE CODE AND WIGGLE TEST THE CONNECTOR. IF THE WIGGLE TEST IDENTIFIES THE CONDITION, EITHER CONNECTOR MAY BE REPLACED WITH SERVICE KIT FOR 1994-1996 7.3L (3C3Z-12224-BA) OR 1997-2003 7.3L OR 2003 6.0L (3C3Z-12224-AA). THE PACKAGE CONTAINS A CONNECTOR WITH PIGTAIL, 3 BUTT SPLICES, 3 SHRINK TUBES AND INSTRUCTIONS. Revised Part Number: 5C3Z-12224-A 16819 1999-2003 VARIOUS VEHICLES - NO CRANK, NO START SOME 1999-2003 VEHICLES MAY EXHIBIT A NO CRANK, NO START CONDITION. THIS MAY BE DUE INADEQUATE TORQUE OF THE STARTER SOLENOID TERMINAL NUTS. TO SERVICE, CHECK THE INTEGRITY OF THE B+ TERMINAL AND S TERMINAL TORQUE. THE B+ TERMINAL NUT SHOULD BE TORQUED TO 12 +/- 1.8 NM AND THE S TERMINAL NUT SHOULD BE TORQUED TO 5.4 +/- 0.9 NM. IF THE CONCERN IS STILL PRESENT, CONTINUE WITH APPROPRIATE PC/ED DIAGNOSTICS. EFFECTIVE DATE: 05/06/2003 16697 1994-2003 F-SUPER DUTIES, 1995-2003 ECONOLINE AND 2000-2003 EXCURSION 7.3L DIT ENGINE MAY EXHIBIT LOWER POWER WHEN COLD, AND AN AIR RUSHING NOISE NORMAL OPERATION - EXHAUST AIR RUSH NOISE AND LOWER POWER. SOME 1994-2003 F- SUPER DUTIES, 1995-2003 ECONOLINE AND 2000-2003 EXCURSION WITH 7.3L ENGINE MAY EXHIBIT LOWER POWER WHEN COLD AND AN AIR RUSHING NOISE. THE TURBO CHARGER EXHAUST IS RESTRICTED BY THE EBP TO HELP INCREASE ENGINE COOLANT TEMPERATURE QUICKER FOR CAB HEAT. THIS IS CONTROLLED BY THE PCM & THE EBP REGULATOR LOCATED IN THE TURBOCHARGER PEDESTAL. THE EBP DEVICE WILL OPEN WHEN THE ACCELERATOR PEDAL IS DEPRESSED CAUSING EXHAUST BACK PRESSURE TO INCREASE. WHEN EXHAUST BACKPRESSURE DECREASES OR THE VEHICLE IS AT A STEADY STATE THE EBP REGULATOR CAN/WILL ACTIVATE THE EBP DEVICE AGAIN EVEN DURING HIGHWAY DRIVING AS LONG AS THE EOT TEMP IS BELOW SPECIFICATIONS. PCM CONTROLLED ON THE FOLLOWING PARAMETERS: IAT BELOW 10C(50F) & EOT BELOW 70C(158F) EFFECTIVE DATE: 03/17/2003 16670 - 6.0L - DRIVE CONCERNS 2003 SUPER DUTY F-SERIES & EXCURSION 6.0L - DRIVE CONCERNS - CAUSED BY POSSIBLE BAD ICP SENSOR SOME 2003 SUPER DUTY F-SERIES/EXCURSION WITH A 6.0L DIESEL MAY EXHIBIT ROUGH, ROLLING IDLE, POOR IDLE RETURN, LOW POWER, INJECTOR FAULT CODES, OR INCREASED SMOKE. THIS MAY BE CAUSED BY THE ICP SENSOR. CAREFULLY INSPECT THE ICP SENSOR CONNECTOR/TERMINALS FOR DAMAGE. VERIFY VREF & SIGNAL RETURN CIRCUITS. IF NO ELECTRICAL ISSUES, USE SCAN TOOL TO MEASURE ICP WITH EOT ABOVE 180 F. KEY OFF, WAIT 1 MINUTE MINIMUM FOR BLEED DOWN. KEY ON, WAIT 30 SECONDS. MONITOR ICP PID (READING SHOULD BE 0.18-0.24 V). IF NOT IN RANGE, CHECK NEW SENSOR (3C3Z-9F838-DA) BEFORE REMOVING OLD SENSOR. ON COOL ENGINE,CONNECT NEW SENSOR TO ICP HARNESS CONNECTOR & ENSURE NO CONTACT WITH ANY METAL COMPONENTS. KEY ON, MEASURE ICP PID (READING SHOULD BE 0.16-0.21 V). IF NOT IN RANGE, CHECK ANOTHER ICP. IF IN RANGE, INSTALL NEW ICP. CK ICP AGAIN ABOVE 180 F PER ABOVE. 16480 1994-2002 F-SERIES SUPER DUTY, EXCURSION, AND ECONOLINE - DTC P0340, POSSIBLE FALSE CODE SOME 1994-2002 F-SERIES SUPER DUTY, EXCURSION, ECONOLINE, ALL EQUIPPED WITH 7.3 DIT DIESEL ENGINE MAY EXHIBIT A FALSE P0340 (DTC). A VALID P0340 SETS WHEN A CMP FAULT CAUSES A NO-START CONDITION. IF A P0340 IS PRESENT WITHOUT A NO-START CONDITION BEING ENCOUNTERED AND NO OTHER CMP DTCS (P0341, P0344) SET, DO NOT REPLACE THE CMP SENSOR. CLEAR THE P0340 DTC AND VERIFY PROPER ENGINE OPERATION. IF THE P0340 IS PRESENT IN COMBINATION WITH OTHER CMP SENSOR CODES, DIAGNOSE THE CMP CIRCUIT AS INSTRUCTED IN THE PCED. EFFECTIVE DATE: 12/18/2002 16258 - 7.3L DIT UVH FALLS OUT 1998-2003 VEHICLES EQUIPPED WITH A 7.3L ENGINE (AFTER SERIAL #0661894) - UNDER VALVE COVER (UVC) HARNESS RETAINER CLIP RELEASED FOR SERVICE SOME 1998-2003 ECONOLINE, SUPER DUTY, F650/7550 & EXCURSION WITH 7.3L (ENG SER #0661894) MAY RUN ROUGH OR MISS DURING HARD ACCELERATION DUE TO A POOR CONNECTION AT THE JUNCTION OF THE INJECTOR/GLOW PLUG HARNESS & THE VALVE COVER GASKET. IF ANY CYLINDER IS IDENTIFIED BY A CYLINDER CONTRIBUTION TEST OR IS SUSPECTED DUE TO INJECTOR PERFORMANCE ANALYZER, REMOVE VALVE COVER GASKET & INSPECT THE CONNECTION BETWEEN THE UVC HARNESS & THE VALVE COVER GASKET. THE LOCKING DEVICE FOR THE UVC MAY BECOME RELAXED & ALLOW THE CONNECTION TO FAIL. A RETAINER 2C3Z-14A163-AB IS AVAILABLE TO INSTALL IN THE LOCKING MECHANISM, SECURING THE CONNECTION. IF THE CONNECTION IS NOT SECURE, INSTALL THE CLIP & RE-EVALUATE THE ENGINE'S PERFORMANCE. DO NOT REPLACE THE INJECTOR(S) IF THE CLIP REPAIRS THE CONDITION. 16244 2000-2002 F-SERIES - BI-FUEL CNG/LPG NEW HEATED OXYGEN SENSOR (HEGO) DIAGNOSTIC CODES SOME 2000 TO 2002 F-SERIES BI-FUEL CNG AND LPG TRUCKS MAY EXHIBIT UNDEFINED SERVICE CODES MAY APPEAR IN THE ALTERNATE FUEL CONTROL MODULE (AFCM) (COMPUVALVE) DUE TO UPGRADED DIAGNOSTICS. IF A CODE P2195, P2196, P2197, OR P2198 OCCURS IN THE AFCM, REFER TO DIAGNOSTIC PROCEDURES AS OUTLINED IN THE 2003 F-SERIES PC/ED. CODE DEFINITIONS: P2195 - HO2S SIGNAL STUCK LEAN (BANK 1, SENSOR 1) P2196 - HO2S SIGNAL STUCK RICH (BANK 1, SENSOR 1) P2197 - HO2S SIGNAL STUCK LEAN (BANK 2, SENSOR 1) P2198 - HO2S SIGNAL STUCK RICH (BANK 2, SENSOR 1) EFFECTIVE DATE: 09/19/2002 16063 1994-2003 CARS & TRUCKS, CAMSHAFT POSITION (CMP) SENSOR ALIGNMENT TOOL CHART SOME SERVICE MANUALS MAY LIST THE INCORRECT CAMSHAFT POSITION SENSOR (CMP) ALIGNMENT TOOL. REFER TO THE FOLLOWING: *T89P-12200-A (303-358)APPLIES TO: 1995 3.8L WINDSTAR,1994-1995 3.8L T-BIRD/COUGAR & MUSTANG. *T93P-12200-A (303-453) APPLIES TO: 1995 3.0L-2V TAURUS/SABLE. *T95T-12200-A (303-529) APPLIES TO: 1995- 1997 3.0L-2V WINDSTAR, AEROSTAR, RANGER), 1996-1997 3.0L-2V TAURUS, SABLE & 1996 -1998 4.0L AEROSTAR, RANGER, EXPLORER. *T96T-12200-A (303-562) APPLIES TO:1996- 1997 3.8L T-BIRD/COUGAR,1996-1998 3.8L MUSTANG,WINDSTAR,1997-2003 4.2L ECONOLINE , F-SERIES & 1996-1998 5.0L EXPLORER, MOUNTAINEER. *303-589 APPLIES TO: 1998- 2003 3.0L-2V TAURUS/SABLE, RANGER & 1998-2000 3.0L-2V WINDSTAR. *303-630 APPLIES TO: 1999-2003 3.8L WINDSTAR,MUSTANG & 1999-20005.0L EXPLORER,MOUNTAINEER. *303-638 APPLIES TO:1999-2000 4.0L EXPLORER,RANGER. EFFECTIVE DATE: 07/26/2002 15661 CALIPER PIN RATTLE SOME 1999-2002 SUPER DUTY F-SERIES (250-350) AND 2000-2002 EXCURSIONS MAY EXHIBIT A RATTLE NOISE ORIGINATING FROM THE FRONT BRAKE CALIPERS. THIS MAY BE CAUSED BY THE CALIPER PINS. IF NORMAL DIAGNOSTICS LEAD TO THE CALIPER PINS, REPLACE THE EXISTING PINS WITH THE NEW BUSHED CALIPER PINS - 2C3Z-2C150-AA (1 KIT REQUIRED PER SIDE). NOTE: SILVER PIN W/BUSHING AND BOOT IS FOR THE LOWER SIDE OF THE CALIPER. GREEN PIN W/NO BUSHING AND BOOT IS FOR THE UPPER SIDE (BLEEDER SIDE) OF THE CALIPER. EFFECTIVE DATE: 02/25/2002 15578 - ABS MODULE CONFIGURATION, USE NGS TO CONFIGURE SOME 1999-2002 F-SERIES SUPER DUTY AND EXCURSION VEHICLES MAY EXHIBIT AN ABS LIGHT ON, B2141/B2477, AND/OR AN INACCURATE SPEEDOMETER. THIS MAY BE DUE TO AN INACCURATELY OR NON-PROGRAMMED ABS MODULE. TO SERVICE, USE NGS ONLY TO PROGRAM ABS MODULE USING THE FOLLOWING PROCEDURE. SELECT SERVICE BAY FUNCTIONS, ABS, TIRE SIZE/AXLE RATIO CONFIGURE, SELECT VEHICLE, ENTER CORRECT REVS/MILE AND AXLE SIZE. TO DETERMINE CORRECT REVS/MILE FOR A TIRE, DIVIDE THE ACTUAL CIRCUMFERENCE OF THE TIRE IN INCHES INTO 63360. FOR EXAMPLE, A 91" TIRE CIRCUMFERENCE WOULD EQUAL 696. YOU THEN ADD TWO ZEROES IN FRONT OF IT FOR NGS TO EQUAL 00696. FOR AXLE SIZE, SCROLL THROUGH OPTIONS AND SELECT THE APPROPRIATE ENTRY. ENGINEERING IS CURRENTLY WORKING ON A CALIBRATION FOR USE WITH THE WDS. 15518 NO START, NO DTC'S STORED, CHECK CKP SENSOR POLARITY SOME 1990-2002 VEHICLES EQUIPPED WITH A CRANKSHAFT POSITION SENSOR (CKP) MAY EXHIBIT A CRANK/NO START AFTER A CKP WIRING/CONNECTOR REPAIR. IF A CRANK/NO START CONDITION OCCURS AFTER REPAIRING THE TERMINALS ON A CKP SENSOR CONNECTOR, VERIFY TERMINAL POLARITY. PCM OR EDIS SOFTWARE INCORPORATE A STRATEGY THAT DOES NOT ALLOW THE MODULE TO PROCESS A REVERSED SIGNAL WAVEFORM. EFFECTIVE DATE: 01/07/2002 17508 2003-2004 SUPER DUTY F-SERIES/EXCURSION/E-SERIES 6.0L - FALSE DTC'S SET DURING USE OF ACTIVE COMMANDS WITH WDS SOME 2003-2004 SUPER DUTY F-SERIES, EXCURSIONS AND E-SERIES VEHICLES EQUIPPED WITH A 6.0L DIESEL ENGINE MAY GENERATE FALSE DIAGNOSTIC TROUBLE CODES (DTC'S) DURING THE USE OF ACTIVE COMMANDS WITH THE WDS. COMMAND OF EGR%, VGT% AND IPR CAN GENERATE THE FOLLOWING DTC'S: P0404, P0488, P0299 (EGR%); P2263, P0478 (VGT%); P2284, P2288, P2289 (IPR). DO NOT USE DTC'S SET DURING THE USE OF ACTIVE COMMANDS TO DIAGNOSE THE VEHICLE CONCERN. IT IS IMPORTANT THAT ALL CONTINUOUS MEMORY DTC'S BE ERASED FOLLOWING DIAGNOSTICS USING ACTIVE COMMANDS. NOT CLEARING THESE DTC'S MAY RESULT IN THE MALFUNCTION INDICATOR LAMP (MIL) TURNING ON AND/OR IMPROPER COMPONENT REPLACEMENT ON RETURN SERVICE VISITS. 15355 P1105, P1106 - POSSIBLE FALSE DTC'S SOME 1994-2002 E/F-SERIES AND 2000-2002 EXCURSION EQUIPPED WITH 7.3L DI ENGINE, MAY EXHIBIT FALSE DIAGNOSTIC TROUBLE CODES (DTC'S) P1105, P1106, (UPPER AND LOWER ALTERNATOR FAULTS), EVEN WITH SINGLE ALTERNATOR SYSTEMS. THE DTC'S MAY BE SET FALSELY AS A RESULT OF JUMP STARTING THE VEHICLE. TO SERVICE, DISCONNECT THE BATTERY FOR 10-15 MINUTES, RECONNECT AND RECHECK FOR DTC'S. IF THE CODES ARE STILL PRESENT CONTINUE WITH NORMAL DIAGNOSIS. EFFECTIVE DATE: 10/31/2001 14895 - 4X4 HUBLOCK NVH SOME 1999/2001 F-SUPER DUTY 4X4S MAY EXHIBIT NOISE, VIBRATION AND RATCHETING FROM THE FRONT WHEEL LOCKING HUBS THAT IS INITIATED BY ROAD INDUCED BUMPS OR IMPACTS. THIS CONDITION MAY BE DUE TO A DETERIORATED SPINDLE BEARING IN THE DRIVE HUB ASSEMBLY INTERMITTENTLY BINDING ON THE AXLE SHAFT. REPLACE THE SPINDLE BEARING (C6TZ-3123-A) AND INSPECT THE AXLE SHAFT FOR WEAR. IF NECESSARY, THE OUTBOARD END OF THE AXLE SHAFT (1C3Z-3B387-AA) IS AVAILABLE SEPARATELY. DURING ASSEMBLY, USE HIGH TEMPERATURE 4X4 FRONT AXLE & WHEEL BEARING GREASE (E8TZ-19590-A, ESA M1C198-A). FOR VEHICLES IN SEVERE-USE CONDITIONS, INSPECTION AND LUBRICATION OF THE BEARING PRIOR TO CONDITION ONSET CAN MINIMIZE POTENTIAL DETERIORATION. 14753 - 7.3L TURBO BOLTS LOOSE NEW BOLT KIT RELEASED - SOME 2000-2001 SUPER DUTY F-SERIES, EXCURSIONS AND E-SERIES EQUIPPED WITH A 7.3L DIT ENGINE MAY EXHIBIT LOOSE TURBO BOLTS ON THE TURBO HOUSING. TYPICAL SYMPTOMS RESULTING FROM LOOSE BOLTS INCLUDE, LACK OF POWER AND AN OIL LEAK. TO SERVICE, INSTALL BOLT KIT #1C3Z-9G486-AA (4 REVISED BOLTS IN KIT WITH INSTALLATION INSTRUCTIONS). 14652 - HIGHER STEERING EFFORTS W/SITTING STILL W/BRAKES APPLIED SOME 1999-2001 SUPER DUTY F-SERIES AND 2000-2001 EXCURSIONS MAY EXHIBIT HIGHER THAN NORMAL STEERING EFFORTS WHEN THE VEHICLE IS AT A VERY LOW SPEED OR STOPPED WITH THE BRAKES APPLIED. THIS IS A NORMAL CONDITION AND MAY BE PRESENT WITH EITHER HYDROBOOST OR VACUUM OPERATED BRAKES; THEREFORE REPAIR ATTEMPTS SHOULD NOT BE MADE. 14514 - CLUNK IN STEERING SOME 1997-2001 E-SERIES MAY EXHIBIT A 'CLUNK' THAT CAN BE FELT OR HEARD THROUGH THE STEERING WHEEL. THE CONDITION IS BEST EXPERIENCED IN A SLIGHT TURN, NEAR 20 MPH, ON ROAD SURFACES WITH SLIGHT IRREGULARITIES. TO SERVICE, REPLACE BOTH THE DOUBLE CARDAN JOINT (1C2Z-3E751-AA) AND LOWER INTERMEDIATE STEERING SHAFT (1C2Z-3B676-AA). DO NOT USE PRIOR LEVEL PARTS AS CONDITION MAY RETURN. REFER TO SECTIONS 211-04 OF THE E-SERIES WORKSHOP MANUAL FOR SERVICE PROCEDURE. TSB 99-09-07 MAY BE REFERENCED FOR THE PROPER PROCEDURE FOR SEATING THE STEERING BOOT. ENSURE THAT THE JOINT/SHAFT RETAINING BOLTS ARE TORQUED TO 21 LB/FT AND ALL SHAFT/JOINT CONNECTIONS ARE FULLY SEATED. NOTE: THIS CLUNK OR FEEL DOES NOT IMPACT THE FUNCTION OF THE STEERING SYSTEM AND IS CONSIDERED A CUSTOMER IRRITATION. 14440 INTERMITTENT INSTRUMENT CLUSTER LAMP PROVE OUT OR PCM RESET SOME 1995-2001 SUPER DUTY F-SERIES AND E-SERIES EQUIPPED WITH 7.3L DIT MAY EXHIBIT INSTRUMENT CLUSTER LAMPS THAT 'PROVE OUT' OR CYCLE WHILE DRIVING WITH A MOMENTARY ENGINE STUMBLE AND THE ACCELERATOR PEDAL NOT RESPONDING UNTIL IT IS RELEASED. THIS MAY BE DUE TO A PCM RESET. A PCM RESET CAN BE CAUSED BY A MOMENTARY SHORT OR OPEN IN 5V REFERENCE OR 12V SUPPLY TO PCM OR IDM AND USUALLY DOES NOT HAVE DIAGNOSTIC TROUBLE CODES STORED. CHECK TSB 97-15A (7.3L DI TURBO DIAGNOSTIC REFERENCE GUIDE) PAGE 115 FOR MORE INFORMATION ON THIS CONDITION. INFORMATION ON 7.3L PCM RESET WILL BE ADDED TO FUTURE VERSIONS OF THE PC/ED. EFFECTIVE DATE: 10/30/2000 14184 IMPROVED ENGINE DIAGNOSTICS - DIESEL ENGINE FUEL CONDITIONERST - SERVICE TIPS: SOME 1999-2000 SUPER DUTY F-SERIES, ECONOLINE AND 2000 EXCURSIONS EQUIPPED WITH 7.3L DIT ENGINE MAY EXHIBIT ONE OR MORE DRIVEABILITY SYMPTOMS, INCLUDING; RUNS ROUGH, MISSES, BUCK/JERK, HESITATE/STUMBLE, SURGE, LACKS POWER, VARIOUS IDLE SYMPTOMS, MIL ON ETC... TO SERVICE, REPROGRAM THE PCM WITH THE LATEST SERVICE RELEASE CALIBRATION. THE LATEST CALIBRATIONS CONTAIN IMPROVED MAP HOSE AND WASTEGATE DIAGNOSTICS. A REVISED CALIBRATION FOR CYLINDER CONTRIBUTION TEST AND EXHAUST BACK PRESSURE (EBP) TO REDUCE THE LIKELIHOOD OF EBP VALVE SURGING IS ALSO CONTAINED IN THE LATEST CALIBRATION. NOTE: DO NOT REPLACE #8 INJECTOR TO UPDATE THE "CACKLE" REPAIR (TSB 00-10-01) FOR ANY SYMPTOM OTHER THAN ENGINE NOISE. REPLACEMENT OF THE #8 INJECTOR IS NOT AUTHORIZED FOR NON-NOISE DRIVABILITY SYMPTOMS REPAIRS.FTER AT LEAST ONE BOTTLE. EFFECTIVE DATE: 06/06/2000 13990 PINPOINT TEST FOR C1113/C1115/C1185 REAR ANTI-LOCK SOME 2000 EXCURSION, SUPER DUTY F-SERIES 250-550 AND F-53 MOTORHOME EQUIPPED WITH 'REAR ANTI-LOCK BRAKES' MAY EXHIBIT ANY OF THE FOLLOWING DIAGNOSTIC TROUBLE CODES; C1113/C1115/C1185. REFER TO THE 2000 EXCURSION/SUPER DUTY F-SERIES WORKSHOP MANUAL '4 WHEEL ANTI-LOCK' SECTION 206-09B FOR PINPOINT TEST 'K'. THE PINPOINT TEST WAS NOT INCLUDED IN THE 'REAR ANTI-LOCK SECTION' OF THE 2000 SERVICE MANUAL. EFFECTIVE DATE: 03/20/2000 13965 XC3Z-9229-AA - O-RING KIT USES PINK 1-PIECE CENTER SEAL FUEL INJECTORS FOR 1994 1/2 AND NEWER F-SERIES, ECONOLINE, EXCURSION, & F650/750 7.3L DIT EQUIPPED VEHICLES ARE NOW SERVICED WITH FUEL INJECTOR O-RING KIT XC3Z-9229-AA. AN IMPROVED SINGLE MIDDLE SEAL THAT IS PINK IN COLOR REPLACES THE SINGLE BLUE O-RING OR THE EARLY STYLE GREEN OR BLACK SEAL WITH CUSHION RING. THE NEW PINK SEAL MEASURES APPROXIMATELY 4.91 MM THICK. ONE KIT IS REQUIRED PER INJECTOR AND THIS KIT IS TO BE USED WHEN SERVICING ALL PREVIOUS DIT ENGINES. EFFECTIVE DATE: 03/10/2000 13590 P0500 ADDITIONAL DIAGNOSIS INFORMATION SOME 1999-2000 SUPER DUTY F-SERIES WITHOUT POWER WINDOWS OR LOCKS, BUILT FROM 1/1/1998 THROUGH 11/1/1999 MAY EXHIBIT ONE OR ALL OF THE FOLLOWING CONCERNS INTERMITTENTLY: MIL ON, ERRATIC AUTOMATIC TRANSMISSION SHIFTING, & DTC P0500 STORED IN MEMORY. IF THE SPEEDOMETER DOES NOT EXHIBIT ANY PROBLEMS, AND THE VEHICLE IS NOT EQUIPPED WITH THE POWER EQUIPMENT GROUP (POWER WINDOWS AND LOCKS), THEN THERE MAY BE A FAULTY CTM/GEM MODULE FEEDING BACK VOLTAGE ONTO THE VSS LINE UNDER CERTAIN CONDITIONS. TO DIAGNOSE, HAVE AN ASSISTANT MONITOR THE PCM VSS PID WHILE DRIVING. IF THE VSS PID IS ZERO ALL THE TIME, OR GOES TO ZERO WHILE DRIVING THE CTM/GEM MODULE MAY BE AT FAULT. FOR THIS FAILURE MODE, THE SPEEDOMETER WILL STILL READ ACCURATELY WHEN THE PCM VSS PID GOES TO ZERO. ONLY CTM/GEM MODULES WITH SUFFIX A-LEVEL OR F-LEVEL ARE AFFECTED. IF THE VEHICLE HAS POWER EQUIPMENT OR THE VSS PID DOES NOT GO TO ZERO, FOLLOW THE STANDARD PINPOINT TESTS OR OTHER RELATED SERVICE MESSAGES. EFFECTIVE DATE: 12/03/1999 13548- IDLE KICKER ACTIVE AFTER 130 SECONDS THE 1999.5 (DECEMBER 1998 AND AFTER) 2000-2001 SUPER DUTY F-SERIES TRUCKS AND 2000-2001 EXCURSIONS EQUIPPED WITH THE 7.3L DIT HAVE A STRATEGY THAT INCLUDES A COLD WEATHER IDLE KICKER FEATURE WHICH, UNDER CERTAIN CONDITIONS WILL AUTOMATICALLY ELEVATE THE IDLE SPEED AFTER 130 SECONDS OF IDLING AT COLD TEMPERATURES. THIS FEATURE RAISES THE IDLE SPEED UP TO A MAXIMUM OF 1200 RPM, BASED ON AIR CLEANER INLET TEMPERATURE AND THE ENGINE OIL TEMPERATURE. FOR THIS FEATURE TO BE ACTIVATED, THE TRUCK MUST BE IN PARK, (FOR THE 4R100 AUTO TRANS), OR IN NEUTRAL WITH PARKING BRAKE APPLIED (FOR M6OD MANUAL TRANS) AND ENGINE OIL TEMP BELOW 70 DEGREES CELSIUS. IDLE KICKER ACTIVE AFTER 130 SECONDS. IF ANY PEDAL OR CONTROL IS MOVED, THE ENGINE RETURNS TO BASE IDLE SPEED AND THE TIMER STARTS OVER. THIS STRATEGY RAISES THE RPM LEVEL TO THE POINT WHERE THE EBP (EXHAUST BACK PRESSURE) WORKS AND WARMS UP THE ENGINE. THE INTENT IS TO ALLEVIATE THE TENDENCY (COMMON TO ALL DIESELS) TO PRODUCE "COKING OR WET STACKING" WHEN IDLED FOR PROLONGED PERIODS AT COLD TEMPERATURES. NOTE: THESE HIGHER IDLE SPEEDS WILL HAVE A DIRECT IMPACT ON FUEL CONSUMPTION. THIS WILL ALSO CREATE A "WHOOSHING" SOUND ASSOCIATED WITH THE ACTIVATION OF THE EBP, THIS IS A NORMAL CONDITION. 4968 - 2003-2005 EXCURSION/2003-2006 F-SUPER DUTY - 6.0L DIESEL - HFCM HEATER DELETE SOME 2003-2005 EXCURSIONS AND 2003-2006 F-SUPER DUTY VEHICLES EQUIPPED WITH A 6.0L DIESEL, BUILT PRIOR TO 5/16/2005, MAY REQUIRE REPLACEMENT OF THE HFCM OR MANIFOLD ASSEMBLY. THE HEATER WAS REMOVED FROM MANIFOLDS ON VEHICLES BUILT BEGINNING 5/16/2005, AND ALL MANIFOLD/SENSOR SERVICE PARTS. THERE IS A JUMPER HARNESS AVAILABLE (P/N 6C3Z-9F759-A) TO ADAPT THE EXISTING HARNESS TO THE UPDATED MANIFOLD/MODULE. A TSB WITH REVISED KIT INCLUDING ALL THE NECESSARY COMPONENTS IS BEING DEVELOPED AND WILL BE AVAILABLE BY THE END OF THE 4TH QUARTER 2005. 4400 - 2005-2006 F-SUPER DUTY - INSTALLATION OF UPFITTER SWITCHES ON TRUCKS NOT ORIGINALLY EQUIPPED FROM THE FACTORY TO INSTALL THE UPFITTER SWITCHES ON A 2005-2006 F-SUPER DUTY, THAT WAS NOT ORIGINALLY EQUIPPED FROM THE FACTORY, ORDER 5C3Z-14A303-AA (WIRE ASY), 5C3Z- 13D730-AAA (SWITCH ASY), AND 5C3Z-2513546-CAA (BOX - UTILITY - LESS HOUSING). THE WIRING HARNESS BOLTS ON, AND THE SWITCH PLUGS INTO IT. THE UTILITY BOX IS ONLY NEEDED IF THE TRUCK IS NOT EQUIPPED WITH A TRAILER BRAKE CONTROLLER. IT MAY BE NECESSARY TO REMOVE THE INSTRUMENT PANEL TO INSTALL THE HARNESS FROM THE BULKHEAD SIDE. REFERENCE Q-117 WHICH CAN BE FOUND AT HTTPS://WWW.FLEET.FORD.COM/TRUCKBBAS/TOPICS/QVMP.HTML FOR ADDITIONAL INFORMATION IF NEEDED. 4399 - 1999-2006 F-SUPER DUTY/2000-2005 EXCURSION - LACK OF A/C COOLING - EVACUATE AND RECHARGE THE A/C SYSTEM SOME 1999-2006 F-SUPER DUTY AND 2000-2005 EXCURSION VEHICLES MAY EXHIBIT A LACK OF A/C COOLING AT HIGHWAY SPEEDS. THIS MAY BE CAUSED BY RAPID CYCLING OF THE A/C COMPRESSOR CLUTCH DUE TO LOW SUCTION PRESSURES. TO SERVICE VEHICLES BUILT BEFORE 7/18/04, EVACUATE AND RECHARGE A/C SYSTEM WITH: - 45 OZ (1.28 KG) OF R134A ON VEHICLES WITHOUT AUXILIARY AIR. - 68 OZ (1.93 KG) OF R134A ON VEHICLES WITH AUXILIARY AIR (EXCURSION ONLY). THE LABEL ON THESE VEHICLES WILL INDICATE A DIFFERENT RECOMMENDED CHARGE LEVEL. ALL VEHICLES BUILT AFTER 7/18/2004 RECEIVED THIS REVISED CHARGE WHEN PRODUCED, BUT THE LABEL HAS NOT YET BEEN UPDATED IN PRODUCTION. FOR VEHICLES BUILT AFTER 7/18/04, AND ALL OTHER LACK OF A/C COOLING SYMPTOMS, REFER TO SECTION 412-00 OF THE WORKSHOP MANUAL FOR NORMAL DIAGNOSTICS. 3848 - 2002/03 F-Series and Excursion Belt Squeal; 99-01 with replaced belts: Some 7.3 engines may exhibit a loud squeal noise from the engine area when the engine is under load and the fan clutch is locked up, typically in hot and dusty conditions. Another complaint may be the fan clutch oscillating or not locking up. This may be due to dust accumulating on the back side of the belt and causing it to slip on the water pump pulley. This usually affects only the 2002 model/year vehicles, but may occur in trucks built from 99-01 if the belt was replaced after July 01. On single rear wheel trucks, replace the serpentine belt with P/N 1C2Z-8620-NA on single alternator engines, and 1C2Z-8620-PA on dual-alternators. 0718 A service kit had been released for 2002 trucks that includes a belt, tensioner and water pump pulley. Use 2C3Z-8620-AA for single alternator and 2C3Z-8620-BA for dual alternators. 9998 - COPYRIGHT 2002-2006 FORD MOTOR COMPANY. ALL RIGHTS RESERVED.

A taxpayer voting for Obama is like a chicken voting for Colonel Sanders.

Isn't Ford's new credo "if it ain't broke we ain't paying to replace it?" I have always bent them back, also without further issues. I have also been fortunate that I have yet to see a branch tube failure in my shop. Ever! (knocks very hard on his desk) /forums/images/%%GRAEMLIN_URL%%/whistle.gif

Make sure that you print out Hot-Line call logs as soon as you see them including updates and post repair. I have had problems with disappearing information.

Well, not likely actually. I was very clear with both of my new techs about being sure converters are fully seated. Nunan here is a careful young guy. Now I am involved a little deeper as his team leader. The engine is making a ticking/rattling noise, shows three cylinders 5% or more low on relative compression and misses on one of those cylinders. Looks like he has a little dis' assemblin to do! This is a remanufactured long block.

Speaking of denied claims. Stupid strikes again! My only certified diesel tech performed TSB 08-07-3 and obviously did not perform the diagnostics properly. Had to go back in to replace the oil cooler and expected to claim an extra 5 hours of M-time to do it. /forums/images/%%GRAEMLIN_URL%%/boink3.gif Warranty Administrator "light" gets the full BS story from this guy and figures it will fly. When the claim bounces the real Warranty Administrator asks me why or how this happens. /forums/images/%%GRAEMLIN_URL%%/shrug.gif Sometimes we really do deserve it. I now have two new issues to try to correct. /forums/images/%%GRAEMLIN_URL%%/frown.gif

Years ago a guy came in with his pick-up after having Jiffy Lube change ALL of his fluids. They even changed his ATF to gear lube in his ZF trans for him. How nice of them! IT wouldn't shift so I doubt anything happened as a result. I changed the fluid, actually driving it and changing it again two more times before it shifted right. Point is, it was fine after a couple of changes and fluid changes are way cheaper than syncros it probably doesn't need. /forums/images/%%GRAEMLIN_URL%%/wink.gif

Finally a way to beat warranty time on 6.0L head gaskets! That will torque them down in a jiffy!!! /forums/images/%%GRAEMLIN_URL%%/whistle.gif

I have had the same problem for many years. I am currently working on an ambulance that has been to 4 separate dealers and none of them have have left a good impression on the customer, and now me. Long story short, it's a rotted out fuel tank requiring fuel lines, secondary filter housing, lines and of course all 8 injectors. There are missing fasteners, loose fasteners, broken fasteners, poorly repaired broken bolts, broken fan stator... this is why they seek out certain dealers. On the flip side, I have also seen a few customers migrate away from my dealer because of long completion times due to being over-booked and under staffed over the last several years. I have also had a few technicians working with me that have caused problems. I'll leave it at that. When it comes to the numbers, I could care less. I take care of the customers, I repair the vehicles and I follow the rules. Nobody is perfect but that does not mean we stop trying. Though I am mindful of the big picture, I don't need a report to dictate or affect how I perform my duties simply because the numbers don't fall in line.

You can't have any pudding if you don't eat your meat... or fix it the second time around.

Is there a tool to release the clutch pedal push rod that goes into the hydraulic master cylinder?

Anyone else seeing issues with front brakes rattling on 2008 Econolines? I have a customer with a fleet of vans that are rattling, replaced front pads to get new anti rattle clips and discovered the clips are not really well designed or effective. They work at first but they appear to weaken and collapse. I know my SM is involved and may have contacted the Hot-Line and ordered new linings for this customer. SM on vacation... not sure if there is supposed to be new clips or some change but the parts I put on were identical to the ones I removed. *and* I also noted on the pre repair road test that the brake pedal was low on first application and pumped up on a second application. The wheel bearings were a little looser than I would have liked and I am not sure if that was causing this concern or whether the clips had anything to do with it. I adjusted the bearings, the noise is gone and the pedal is nice... ... but for how long?

Mike, Someone here informed some time ago about the fitting when we first learned of it. The fitting started going into V8 engines starting with Engine ser# 431736 on 2/9/07. That is the best info I have for you. In any event, this means that not all 2007 model trucks will have the new part.

No obvious leaks in the intake as far as I can see and the filter, besides being dirty, is in good condition, fits properly and the filter minder has not moved. I am tempted to spend my own $20 for a sample analysis just to see what it says.

I recall the ACERT program training to be difficult simply due to the fact that for me there was little CAT specific training base. Many of the topics would have been easier to comprehend if I had more training on specific engines and systems. Something like the failure analysis would be a great basic course though.