Recalls for '80-96 Broncos & F-series

[Steve83]

TSB 91-12-11 Converter Diagnosis
Publication Date: JUNE 12, 1991

LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES
1988-91 F SUPER DUTY, F47

ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation.

ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details.

SERVICE PROCEDURE
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECIEVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
* Ignition Coil
* Distributor Cap
* Distributor Rotor
* Fouled Spark Plug
* Spark Plug Wires
* Air Filter
* Stuck Open Injector
* Fuel Contamination Engine OIL
* Manifold Leaks Intake/Exhaust
* Fuel Pressure
* Poor Power Ground
* Engine Not At Normal Operating Temperature
* HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20° BTDC ± 3°.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire.
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI ± 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. Visually inspect the throttle body and linkage for:
* Binding or sticking throttle linkage.
* Tight speed control linkage or cable.
* Vacuum line interference.
* Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS
NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.

OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage

OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform KOEO And KOER Self Tests 0.5 Hrs.
911211B Timing - Check Or Adjust Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer 0.5 Hrs.
911211C Check - Fuel Pressure And Inspect Vacuum Line For Raw Fuel 0.2 Hrs.
911211D Inspect - Throttle Body And Linkage 0.1 Hrs.
911211E Inspect - Vacuum Hoses, Electrical Harnesses, Connectors And Spark Plug Wires For Routing Damage 0.1 Hrs.
911211F Thermactor System - Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass
Solenoid, Check Valves, Silencer And Filter 0.3 Hrs.
911211G Thermostat - Check For Proper Operation 0.2 Hrs.

[Steve83]

TSB 91-20-12 A/C Pressure Relief Leak
Publication Date: OCTOBER 2, 1991

LIGHT TRUCK: 1987-91 BRONCO, F-150-350 SERIES
1988-91 F SUPER DUTY, F-47

ISSUE: There may be a loss of A/C refrigerant through the A/C compressor high relief valve during idle and stop-and-go traffic conditions. Eventually, there may be a lack of cooling and oil stains may appear around the A/C compressor high pressure relief valve. The excessive discharge pressure is caused by the recirculation of higher temperature engine compartment air passing through the condenser during idle and stop-and-go traffic conditions. Normally, cooler ambient air passes through the condenser. Since the refrigerant in the condenser cannot be sufficiently cooled by this high temperature air, excessive head pressures are created causing refrigerant to be vented through the high pressure relief valve.

ACTION: Replace the radiator lower air shield, located between the lower radiator support and the front bumper, with a new radiator lower air deflector (F1TZ-8327-B). This new air deflector is larger than the old air shield and will minimize the amount of hot air recirculation through the condenser. Refer to the 1991 Bronco, Econoline, F-Series, F-Super Duty Truck Shop Manual, Section 01-08, for service details.
NOTE: TO REPLACE THE DEFLECTOR ON OLDER VEHICLES, IT WILL BE NECESSARY TO DRILL HOLES, FOLLOWING THE HOLE PATTERN IN THE NEW DEFLECTOR, BEFORE IT CAN BE ATTACHED.

PART NUMBER PART NAME
F1TZ-8327-B Radiator Lower Air Deflector

OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 91-14-13
WARRANTY STATUS: Eligible Under Basic Warranty Coverage

OPERATION DESCRIPTION TIME
912012A Install New Air Deflector 0.4 Hr.

[Steve83]

TSB 92-11-10 Fuel Stabilizer
Publication Date: MAY 20, 1992

LIGHT TRUCK: 1988-90 BRONCO II
1988-92 AEROSTAR, BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES, F-47, F-53, RANGER
1991-92 EXPLORER

ISSUE: During extended periods of vehicle storage (60 days or more), gasoline may deteriorate due to oxidation. This may damage rubber components and other polymers in the fuel system. It may also eventually clog small orifices in the fuel charging system.

ACTION: Add Ford Gas Stabilizer (E8AZ-19C544-A) or an equivalent commercially available fuel stabilizer such as "STA-BIL" to the vehicle's fuel tank whenever the actual or expected storage periods exceed 60 days. The instructions packaged with the product should be closely followed. The vehicle should be operated at an idle speed to circulate the additive throughout the fuel system.

PART NUMBER PART NAME
E8AZ-19C544-A Gas Stabilizer

OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 87-7-16
WARRANTY STATUS: INFORMATION ONLY

[Steve83]

TSB 92-17-8 Front Seat Clunks
Publication Date: AUGUST 12, 1992

LIGHT TRUCK: 1992 BRONCO, ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER

ISSUE: A "clunk" may be heard when accelerating, stopping or turning. This is normally caused by the manual front seat track latch mechanism.

ACTION: Check seat track latches and mechanisms for proper torque and alignment. Refer to the following diagnostic service procedure for details.

FRONT MANUAL SEAT DIAGNOTIC - SERVICE PROCEDURE

Econoline - Passenger's Side Front Bucket Seat On Pedestal Equipped With Under - Seat Storage:
1. Check to see if all pedestal to floor and seat track to seat cushion attachments are properly secured and torqued to specification, so that the "clunk" is not due to loose attachments. Refer to Section 01-10A of the 1992 Service Manual for the required torque specifications.
a. If the seat was properly secured, proceed to Step 2.
b. If the seat was not properly secured, torque all required attachments to Service Manual specifications and check to see if the "clunk" has been corrected. If not, proceed to Step 2.
2. Check to see if both seat track latches are fully engaged after a normal fore-aft adjustment.
a. If yes, the "clunk" is not due to the latch mechanism.
b. If not, the seat is not synchronized. Proceed to Step 3.
3. Disconnect the electrical connector for the power lumbar, If so equipped.
4. Remove the complete seat and pedestal assembly from the vehicle. Refer to the Service Manual.
5. Move the seat full front. Loosen the seat track to seat pedestal rear attachments.
6. Move the seat full rear.
7. Loosen the seat track to seat pedestal front attachments.
8. Check the engagement and alignment of the seat track latches.
9. Check the retention of the tie wire.
10. Secure and torque the seat track to pedestal front attachments to Service Manual specifications.
12. Move the seat full front.
13. Secure and torque the seat track to seat pedestal rear attachments to Service Manual specifications.
14. Connect electrical connector for the power lumbar, If so equipped.
15. Install the complete seat and pedestal assembly in the vehicle and torque the floor attachments to Service Manual specifications.
16. Check the seat for proper operation. (After a normal fore-aft adjustment, the seat should be fully latched at both sides).
17. Verify the "clunk" has been corrected.

Econoline And Aerostar Driver's Side Bucket Seat On Pedestal:
1. Check to see if all seat track to floor and seat track to seat cushion attachments are properly secured and torqued to specification, so that the "clunk"
is not due to loose attachments. Refer to Section 01-01A of the 1992 Service Manual for the required torque specifications.
a. If the seat was properly secured, proceed to Step 2.
b. If the seat was not properly secured, torque all required attachments to the Service Manual specifications and check to see if the "clunk" has been
corrected. If not, proceed to Step 2.
2. Check to see if both seat track latches are fully engaged after a normal fore-aft adjustment.
a. If yes, the "clunk" is not due to the latch mechanism.
b. If not, the seat is not synchronized. Proceed to Step 3.
3. Move the seat full front.
4. Loosen the seat track to pedestal rear attachments.
5. Move the seat full rear. Loosen the seat track to pedestal front attachments.
6. Illuminate seat underneath in the front. Check engagement and alignment of seat latches.
7. Check tie wire retention.
8. Secure and torque the seat track to pedestal front attachments to Service Manual specifications.
9. Move the seat full front.
10. Secure and torque the seat track to seat pedestal rear attachments to Service Manual specifications.
11. Check the seat for proper operation. (After a normal fore-aft adjustment, the seat should be fully latched at both sides.)
12. Verify that the "clunk" has been corrected.

Ranger Standard Cab - Bucket Seat Or 60/40 Seat; Ranger Standard Cab, F-Series Standard Cab, And Bronco - Bench Seats:
1. Check to see if all seat track to floor and seat track to seat cushion attachments are properly secured and torqued to specifications, so that the "clunk"
is not due to loose attachments. Refer to section 01-10A of the 1992 Service Manual for the required torque specifications.
a. If the seat was properly secured, proceed to Step 2.
b. If the seat was not properly secured, torque all required attachments to Service manual specifications and check to see if the "clunk" has been corrected. If not, proceed to Step 2.
2. Check to see if both seat track latches are fully engaged after a normal fore-aft adjustment.
a. If yes, the "clunk" is not due to the latch mechanism.
b. If not, the seat is not synchronized. Proceed to Step 3.
3. Move the seat full front.
4. Loosen the seat track to floor rear attachments.
5. Move the seat full rear. Loosen the seat track to floor attachments.
6. Illuminate seat underneath in the front. Check engagement and alignment of seat track latches.
7. Check tie wire retention.
8. Secure and torque the seat track to pedestal front attachments to Service Manual specifications.
9. Move the seat full front.
10. Secure and torque the seat track to floor rear attachments to Service Manual specifications.
11. Check the seat for proper operation. (After a normal fore-aft adjustment, the seat should be fully latched at both sides.
12. Verify the "clunk" has been corrected.

Explorer 4-Door - Bucket Seat Or 60/40 Seat; Ranger Standard Cab - DSO Seat:
1. Check to see if all seat track to floor and seat track to seat cushion attachments are properly secured and torqued to specifications, so that the "clunk" is not due to loose attachments. Refer to Section 01-10A of the 1992 Service Manual for the required torque specifications.
a. If the seat was properly secured, proceed to Step 2.
b. If the seat was not properly secured, torque all required attachments to Service Manual specifications and check to see if the "clunk" has been corrected. If not, proceed to Step 2.
2. Check to see if both seat track latches are fully engaged after a normal fore-aft adjustment.
a. If yes, the "clunk" is not due to the latch mechanism.
b. If not, the seat is not synchronized. Proceed to Step 3.
3. Move the seat full front.
4. Remove the seat to floor insulators (if so equipped).
5. Remove only rear hook of assist spring.
6. Loosen the seat track to floor rear attachments.
7. Move the seat full rear.
8. Loosen the seat track to floor front attachments.
9. Illuminate seat underneath in the front. Check engagement and alignment of seat track latches.
10. Check tie wire retention.
11. Secure and torque the seat track to floor front attachments to Service Manual specifications.
12. Move the seat full front. Install rear hook of the assist spring.
13. Secure and torque the seat track to floor rear attachments to Service Manual specifications.
14. Install the seat to floor rear insulators (if so equipped).
15. Check the seat for proper operation. (After a normal fore-aft adjustment, the seat should be fully latched at both sides).
16. Verify the "clunk" has been corrected.

Ranger Super Cab, Explorer 2-Door, F-Series Super Cab, and Bronco with Tip Slide Seat:
1. Check to see if all seat track to floor and seat track to seat cushion attachments are properly secured and torqued to specifications, so that the "clunk" is not due to loose attachments. Refer to Section 01-10A of the 1992 Service Manual for the required torque specifications.
a. If the seat was properly secured, proceed to Step 2.
b. If the seat was not properly secured, torque all required attachments to Service Manual specifications and check to see if the "clunk" has been corrected. If not, proceed to Step 2.
2. Check to see if both seat track latches are fully engaged after a normal fore-aft adjustment.
a. If yes, the "clunk" is not due to the latch mechanism.
b. If not, the seat is not synchronized. Proceed to Step 3.
3. Move seat full front. (Use the under-seat adjustment lever only.)
4. Remove seat to floor rear insulators.
5. Loosen seat track to floor rear attachments.
6. Move seat full rear. (Use the under-seat adjustment lever only.)
7. Loosen the seat track to floor front attachments.
8. Illuminate seat underneath in the front. Check engagement and alignment of seat track latches.
9. Check tie wire retention.
10. Secure and torque the seat track to floor front attachments to Service Manual specifications.
11. Move the seat full front. (Use the under-seat adjustment lever only.)
12. Secure and torque the seat track to floor rear attachments to Service Manual specifications.
13. Install the seat to floor rear insulators.
14. Check the seat for proper operation. (After a normal fore-aft adjustment, the seat should be fully latched at both sides.)
15. Verify the "clunk" has been corrected.

OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage

OPERATION DESCRIPTION TIME
921708A Passenger Side Front Bucket Seat On Pedestal Equipped With Underseat Storage (Includes Seat Assembly Removal) - Econoline 0.6 Hr.
921708B Driver's Side Bucket Seat On Pedestal (Does Not Include Seat Assembly Removal) - Econoline And Aerostar. 0.5 Hr.
921708C Bucket Seat Or 60/40 Seat, Bench Seat (Standard Cab) - Ranger, F-150-350 And Bronco 0.4 Hr.
921708D 4-Door Bucket Seat Or 60/40 Seat (Dealer Special Order) - Explorer Or Ranger Standard Cab 0.5 Hr.
921708E Tip Slide Seat - Ranger Super Cab, Explorer 2-Door, F-Series Super Cab And Bronco 0.5 Hr.

[Steve83]

TSB 92-17-11 Heater Core Replacement
Publication Date: AUGUST 12, 1992

LIGHT TRUCK: 1992 BRONCO, F SUPER DUTY, F-150-350 SERIES

ISSUE: Heater core service procedures have been revised and supersede those found on page 12-03A-35 of the 1992 Light Truck Service Manual.

ACTION: Refer to the following Service Procedure for the revised heater core removal and installation procedures.

SERVICE PROCEDURE
Removal:
1. Allow the engine to cool. Observe the safety precautions as outlined in Section 03-03, Engine Cooling; then, proceed as follows:
a. Place a thick cloth over the radiator cap.
WARNING: NEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITIONS WHILE THE ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR PERSONAL INJURY. TO AVOID HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE RADIATOR, USE EXTREME CARE WHEN REMOVING
THE CAP FROM A HOT RADIATOR. WAIT UNTIL THE ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND TURN IT SLOWLY TO THE FIRST STOP. STEP BACK WHILE THE PRESSURE IS RELEASED FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN RELEASED PRESS DOWN ON THE CAP (STILL WITH A CLOTH),
TURN AND REMOVE IT.
b. Turn the cap slowly to its first stop to release system pressure.
c. When the pressure has been released, tighten the radiator cap.
2. Disconnect the heater hoses from the heater core tubes. Plug the hoses.
3. Remove the glove compartment.
4. Disconnect Bowden cable.
5. Disconnect electrical connector from electrical module.
6. Remove electrical module.
7. From inside the passenger compartment, remove the seven screws which attach the heater core access cover to plenum.
8. Disconnect the vacuum harness attached to the cover. Remove the cover.
9. Remove the heater core from the plenum.

Installation:
1. Position the heater core and seal in the plenum assembly.
2. Install the heater core access cover on the plenum assembly and secure it with its seven attaching screws. Be certain that the vacuum harness is not trapped or pinched during the cover installation.
3. Connect the vacuum harness to its source connection.
4. Install electrical module.
5. Connect electrical module connector.
6. Connect Bowden cable.
7. Install glove box compartment.
8. Install heater hoses on heater core tubes at dash panel in engine compartment. Do not over-tighten the hose clamps.
9. Check coolant level and add coolant as required. Refer to Section 03-03, Engine Cooling.
10. Check system for proper operation and coolant leaks.

OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY

[Steve83]

TSB 93-01-16 Fuel Pulse Damper 4.9L
TSB 93-13-09 Fuel Pulse Damper 5.8L
Publication Date: JANUARY 5, 1993

LIGHT TRUCK: 1992-93 BRONCO, F-150-350 SERIES

ISSUE: A fuel system "knocking" noise may be heard. The noise is caused by fuel injector pulsations that are transmitted through the fuel lines.

ACTION: Install a new front fuel line assembly with a pulse damper. Refer to the following procedure for service details.

SERVICE PROCEDURE
1. Relieve the fuel system pressure. Refer to the 1992 F-150-350, Bronco Service Manual, Page 10-01A-26, for fuel system pressure relief procedure.
2. Remove the existing front frame to engine fuel line assembly. Refer to Figures 1 and 3 for fuel line disconnecting procedures on each end.
3. If any material was installed to isolate the "knocking" noise previously, remove it.
4. Install the new front fuel line assembly (F3TZ-9J338-G or F3TZ-9J338-H) with the pulse damper. Refer to Figures 2 and 3 for installation procedure.
5. Check the system to be sure there are no leaks.

PART NUMBER PART NAME
F3TZ-9J338-G 4.9L Front Fuel Line Assembly (Bronco And Regular Cab F-Series)
F3TZ-9J338-H 4.9L Front Fuel Line Assembly (Super Cab F-Series)
F3TZ-9J338-J 5.8L Front Fuel Line Assy. (F-Series, Regular Cab And Bronco)
F3TZ-9J338-K 5.8L Front Fuel Line Assembly (F-Series Super Cab)

SUPERSEDES: 92-24-11
WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage And 1992 And Later Model Emissions Warranty

OPERATION DESCRIPTION TIME
930116A Replace 4.9L Front Fuel Line 0.4 Hr.
930116A Replace 5.8L Front Fuel Line 0.9 Hr.

[Steve83]

TSB 93-8-13 Replacement A/C Vacuum Reservoir
Publication Date: APRIL 14, 1993

LIGHT TRUCK: 1992-93 BRONCO, F-150-350 SERIES

ISSUE: The vacuum tank for the heater or heater/air conditioning controls is sonically welded to the side of the heater or evaporator case. If a vacuum leak occurs at the vacuum tank, a different vacuum tank can be used to make the repair without removing the old vacuum tank.

ACTION: Install a new service vacuum tank. Refer to the following procedure for service details.

SERVICE PROCEDURE
1. In the engine compartment, detach the vacuum hose from the sonically welded vacuum tank on the heater or evaporator case.
2. Attach the replacement vacuum tank (F3TZ-19D848-A) in a conveniently located spot that can be reached by the vacuum hose. Several areas are available:
a. On the old sonically welded tank, drill an appropriate size hole in the old vacuum tank and use a self-tapping screw to attach the new replacement vacuum tank. The replacement vacuum tank (F3TZ-19D848-A) has slots which will accept the screws.
b. Attach the replacement vacuum tank and put on the vacuum hose.
3. If the old tank mount location is not suitable, locate an existing screw on the blower case and put the replacement vacuum tank (F3TZ-19D484-A) with its slotted bracket in a position over the screw.
a. Make sure of the following points:
* There is room for the tank.
* The vacuum hose will reach it.
* The replacement tank can be attached with that screw.
b. If necessary, rework the slot on the replacement vacuum tank so the screw will fit through it.
c. Attach the replacement vacuum tank and put on the vacuum hose.
4. Verify that the system operates properly.

PART NUMBER PART NAME
F3TZ-19D848-A Vacuum Tank

OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage

OPERATION DESCRIPTION TIME
930813A Install Replacement Vacuum Tank 0.3 Hr.

[Steve83]

TSB 93-22-10 Brake & Clutch Shaft Bushing
Publication Date: OCTOBER 27, 1993

LIGHT TRUCK: 1992 BRONCO, F SUPER DUTY, F-150-350 SERIES

ISSUE: Brake and clutch pedal supports may exhibit excessive bushing wear, lash or squeaking. This may be caused by an insufficient bearing surface for the bushing.

ACTION: Replace the brake and clutch pedal support with an improved design pedal support which provides adequate bearing surface. Refer to the following procedure for service details.

SERVICE PROCEDURE
1. Remove the old brake and clutch pedal support. Refer to the 1992 Body/Chassis Service Manual, Section 08-02.
2. Hold the new brake and clutch pedal support in place by supporting the brake pedal in the "up" position when connected to brake master cylinder pushrod.
3. Tighten the upper cowl bolts to 23.5 ± 3.5 N-m (15 lb-ft).
4. Tighten the brake booster bolts to 26 ± 8 N-m (20 lb-ft).
5. Tighten the master cylinder bolts to 12.25 ± 2.75 N-m (10 lb-ft).
6. Snap the clutch master cylinder pushrod onto the pin of the cross shaft lever.
7. Tighten the cross shaft nut to 80 ± 12 N-m (60 lb-ft).
NOTE: THE CROSS SHAFT NUT MUST BE TIGHTENED LAST FOR PROPER PROCESSING AND FUNCTION.

PART NUMBER PART NAME
F3TZ-2455-A Brake/Clutch Pedal Support Assembly - F-150/250/350/Bronco
F3TZ-2455-B Brake/Clutch Pedal Support Assembly - F-Super Duty

OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage

OPERATION DESCRIPTION TIME
932210A Replace Clutch And Brake Pedal Support Assembly 1.2 Hrs.

[Steve83]

TSB 93-23-14 Gasket Removal
Publication Date: NOVEMBER 10, 1993

FORD: 1988-93 CROWN VICTORIA, ESCORT, FESTIVA, MUSTANG, TAURUS, TEMPO, THUNDERBIRD
1989-93 PROBE
LINCOLN-MERCURY: 1988-89 TRACER
1988-92 MARK VIII
1988-93 COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR
1991-93 CAPRI, TRACER
1993 MARK VIII
MERKUR: 1988-89 SCORPIO, XR4TI
LIGHT TRUCK: 1988-90 BRONCO II
1988-93 AEROSTAR, BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES, RANGER
1991-93 EXPLORER
1993 VILLAGER

ISSUE: Some engine assemblies replaced under warranty have been found to be internally contaminated. This condition may be traceable to a previous repair involving removal of the valve cover(s), intake manifold and cylinder head(s). Scuffed pistons/bores, excessively worn crankshaft/camshaft bearings, low or no oil pressure, engine knocking and excessive oil consumption can result from improper engine gasket surface preparation.

ACTION: Refer to the following TSB article for gasket sealing surface preparation procedures recommended by Ford Motor Company.

SERVICE PROCEDURE
1. Identify the composition of the component part before proceeding with a cleaning operation. Determine whether the part is cast iron, steel, aluminum or plastic. This can usually be distinguished by the inherent hardness and/or weight of the part.
2. If the part is iron or steel, use a scraper with a high carbon blade, for best results. The key is to use a high carbon steel blade that is "razor-sharp." With a sharp blade, very little effort is required to peel off the old gasket.
a. Lay the blade flat on the surface and push slowly and evenly. Don't allow the blade corners to tip in and mar the surface.
b. Rounding off the blade corners with a small grinder will prevent scratching and gouging of the gasket surface.
WARNING: USE EXTREME CARE TO KEEP HANDS AND FINGERS CLEAR OF THE BLADE.
3. If the part is aluminum or plastic, a different scraper must be used. Carbon steel or any other steel edge will cut, mar, gouge or burr aluminum and plastic. A teflon or hard wooden scraper is recommended. First use a commercially-available spray solvent, allowing ample time for the solvent to act on the gasket. A suitable solvent should evaporate and leave no residue behind. Otherwise, the residue can cause a new leak to form.
NOTE: UNDER NO CIRCUMSTANCES ARE ANY GASKET SURFACES TO BE CLEANED AND PREPARED FOR SEALING BY USING A HAND GRINDER, ROTARY WIRE BRUSH, SANDING DISC OR PAD
OR ANY OTHER POWER TOOL USING AN ABRASIVE SURFACE AS A CUTTING TOOL. THESE TOOLS HAVE BEEN FOUND TO PROMOTE ENTRY OF SANDING GRIT AND GASKET MATERIAL INTO ENGINE CAVITIES. THESE TOOLS CAN DAMAGE THE SURFACE FINISH AND POSSIBLY DISTORT THE ORIGINAL FLATNESS OF THE COMPONENT, LEADING TO FURTHER VACUUM, COMPRESSION AND/OR FLUID LEAKS.
4. To prevent gasket material or other foreign matter from entering internal engine compartments, place CLEAN shop towels over exposed cavities. Use extreme care when removing the towels; remove them SLOWLY. Cloth towels can drop as much foreign material into the engine as they originally collected during cleaning operations.
5. Another alternative is to use a portable shop vacuum. Moving a vacuum nozzle closely along with the scraper edge will help direct loosened gasket particles into the vacuum and away from the engine.
6. The same care used in preparing the gasket surface should be practiced when assembling component parts such as the intake manifold and cylinder heads. Both are critical leak areas requiring extra care during assembly. Some things to consider are:
a. Not all engines use the same sealants in the same places. Some parts use no sealant at all.
b. Consult the service manual first. Don't assume that a gasket needs sealant. Some gaskets are designed with a pre-cast bead. Adding sealant to this design type will create a leak by shimming the two mating surfaces.
c. Although some aftermarket gaskets look the same as the ones removed, use only Ford original equipment parts to ensure that the customer receives consistent quality and value.
d. Avoid gasket locating products such as "tack'ems". These chemicals may leave residues in the engine that are incompatible with the oil, and may even cause damage to the catalytic converter.
7. Practice CLEANLINESS when reinstalling components and gaskets.
a. A small leak path can become a larger one as fluid erodes a gasket.
b. Keep dirt, lint and unwanted chemicals off new gaskets.
c. DO NOT assume that once dirt enters the engine that the oil filter will cleanse the oil to its original state and protect the engine from harmful abrasives. Particles such as silica (sand) are small enough to pass through even the best oil filters. The grinding effect of sand and dirt in oil on internal bearing or wear surfaces is comparable to the effect of valve compound for lapping-in valves.
8. Torque sequence of components such as intake manifold and cylinder heads is extremely critical for proper sealing.
a. Not only does sequencing make a more effective seal, it also protects the part from warpage or distortions caused by improper tightening. b. Aluminum is particularly susceptible to warpage from uneven tightening of fasteners.
c. In some instances, fasteners used on aluminum components must be loosened in sequence. Consult the service Manual in EVERY instance for correct torque and/or de-torque values and sequences.
9. After a repair job, it is a good practice to use a black light leak test to confirm that the repair was successful. For example, it would be easy to assume that the rear main crankshaft seal was leaking when in fact the intake manifold gasket allowed oil to run down the back of the engine. Consider all the facts which allow fluid to travel outside the engine (fan air blast, road air blast, gravity, or escaping/pressurized fluid spray.

To sum-up, a successful leak repair depends on:
* Accurate diagnosis of the leak using Ford-recommended test equipment and procedures.
* Surface preparation and gasket installation using the proper cleaning tools.
* Exercising care and cleanliness during assembly/disassembly of components.
* Use of genuine Ford OEM parts.

OTHER APPLICABLE ARTICLES: 92-25-02
WARRANTY STATUS: INFORMATION ONLY

[Steve83]

TSB 98-5A-12 Dolly Towing
Publication Date: MARCH 18, 1998

FORD: 1988-93 FESTIVA
1988-94 TEMPO
1989-96 PROBE, TAURUS SHO
1991-97 ESCORT
1994-96 ASPIRE
LINCOLN-MERCURY: 1988-94 TOPAZ
1991-94 CAPRI
1991-97 TRACER
LIGHT TRUCK: 1988-96 AEROSTAR, BRONCO, E-350, F SUPER DUTY, F-250, F-350, F-53 MOTORHOME, RANGER
1988-97 F-150
1991-96 EXPLORER
1997 MOUNTAINEER

ISSUE: Many motorhome owners tow a vehicle when traveling. Improper techniques can "overload" the brake system of the tow vehicle or damage the drivetrain of the vehicle being towed.

ACTION: Use the information and charts shown in this TSB article to properly match tow vehicle, towed vehicle and towing method.

TOWING METHODS
1. TRAILER - The vehicle is loaded onto and secured to a trailer and simply acts as "secured" cargo.
2. DOLLY - The vehicle is "partially" loaded and partially towed. Either front or rear wheels are loaded and secured to a "towing dolly" and the other wheels roll on the road.
3. TOW BAR - All of the vehicle wheels roll on the pavement. The towed vehicle's steering column must be unlocked so that it can track correctly behind the tow vehicle.

WEIGHT RATINGS AND BRAKES
* GVWR (Gross Vehicle Weight Rating) - is the MAXIMUM allowable weight of the towing vehicle, passengers and cargo
* GCWR (Gross Combined Weight Rating) - is the MAXIMUM allowable weight of the towing vehicle and the weight of the trailer or vehicle being towed, including all passengers and cargo
* BRAKES - The motorhome brakes are designed and rated for the GVWR of that vehicle and will provide adequate braking for trailers and towing vehicles up to 680 kg (1500 lb)
CAUTION: SEPARATE AUXILIARY BRAKES ARE REQUIRED ON TRAILERS OR TOWED VEHICLES OVER 680 KG (1500 LBS). DO NOT CONNECT A TRAILER'S, DOLLY'S OR OTHER TOWED VEHICLE'S BRAKE SYSTEM TO THE TOWING VEHICLE'S BRAKE SYSTEM.

TOWED VEHICLES
1. Trailer-towed - The vehicle should be loaded on the trailer in a manner to achieve a trailer tongue load of 10-15% of total trailer weight, not exceed the trailer or hitch ratings and be securely tied down.
2. Dolly-towed - For front wheel drive vehicles, towing an automatic transaxle (ATX)-equipped vehicle behind another vehicle, such as a Recreational Vehicle (RV), requires that a front wheel dolly or trailer be used.
NOTE: TEMPO ALL-WHEEL DRIVE MODELS MUST BE TRAILER-TOWED. DO NOT TOW THESE VEHICLES USING A TWO-WHEEL TOWING DOLLY.
CAUTION: DO NOT TOW A VEHICLE WITH AN AUTOMATIC (ATX) TRANSAXLE WITH THE DRIVE WHEELS ON THE GROUND. DAMAGE TO THE TRANSAXLE MAY RESULT.
3. Tow Bar-towed - Vehicles which can be successfully towed with a tow bar are listed in the following chart. Additional vehicle-specific information follows the chart.

FORD-BUILT VEHICLES APPROVED FOR DOLLY TOWING
VEHICLE - MANUAL TRANSMISSION - AUTOMATIC TRANSMISSION
FORD CARS
ASPIRE - YES - NO
FESTIVA - YES - NO
ESCORT - YES - NO
TEMPO - YES - NO
PROBE - YES - NO
TAURUS (SHO ONLY) - YES - NO
LINCOLN/MERCURY CARS
TRACER - YES - NO
TOPAZ - YES - NO
CAPRI - YES - NO
FORD TRUCKS
RANGER 4X2 - YES - NO
RANGER 4X4 - YES - YES**
EXPLORER 4X2 - YES - NO
EXPLORER 4X4 - YES - YES**
AEROSTAR 2WD - YES - NO
F-SERIES 4X4 - YES** - YES**
BRONCO 4X4 - YES** - YES**
E-350 - YES - NO
MOUNTAINEER 4X2 - YES - NO
MOUNTAINEER 4X4 - YES - YES**

ALL VEHICLES
NOTE: DO NOT TOW ANY VEHICLE AT A SPEED FASTER THAN 88 KM/H (55 MPH). THE MAXIMUM TOWING DISTANCE (WHEN TOWED CORRECTLY) IS UNLIMITED.
WARNING: NEVER USE A TOW BAR THAT ATTACHES ONLY TO THE BUMPER.

MTX-EQUIPPED VEHICLES
Towing a manual transaxle (MTX)-equipped vehicle with the drive wheels on the ground is acceptable only if the vehicle is towed in a forward direction. The parking brake must be released and the gear shift lever must be in Neutral.
* For Aspire, Festiva, Escort and Tracer, the ignition key must be in the ACC position, the battery must be disconnected to eliminate battery drain, and the steering wheel must be unlocked
* For Capri, the ignition key must be in the OFF position and the steering wheel unlocked
* Refer to the specific vehicle Owner Guide for complete details.
CAUTION: TOWING MTX-EQUIPPED VEHICLES INCORRECTLY MAY RESULT IN TRANSAXLE DAMAGE.

TRUCKS
* The steering wheel must be unlocked by placing the ignition key in the OFF position
* Manual transmission shift lever must be in Neutral
* On 4X4 manual shift transfer cases, the shift lever must be in Neutral
* 4X4 locking hubs (both manual and automatic) must be unlocked
* Refer to the specific vehicle Owner Guide for complete details

OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 93-24-6
WARRANTY STATUS: INFORMATION ONLY

[Steve83]

TSB 94-9-12 PSOM & Visor Screws
Publication Date: MAY 4, 1994

LIGHT TRUCK: 1994 BRONCO, F-150, F-250, F-350

ISSUE: The Instrument Panel Electrical PSOM (Programmable Speedometer/Odometer Module) may be inoperative or not function properly and the #8 fuse may be blown. In addition, if the vehicle is equipped with an E4OD transmission, it may exhibit a harsh shift. These conditions may be caused by trim screws installed through the 17K745 visor wire between the left hand "A" pillar and the left hand visor bullet connector.

ACTION: Tape the damaged or exposed wire conductor and add scrolling to protect the wiring from trim screw shorts. Refer to the following service procedures for service details.

SERVICE PROCEDURE
1. Remove the garnish moulding. Refer to the 1994 Econoline, F-150-350, Bronco F-Super Duty Service Manual, Page 01-05A-5, for the removal procedure.
a. Inspect the wiring condition against the trim screws.
b.Check screws for burn marks.
2. If burn mark is found, use electrical tape to protect exposed/damaged wire. Add 1/4" (6.35 mm) scrolling to maximize protection.
3. Replace #8 fuse.
4. Reset the PSOM to see if it is functioning properly. Refer to the 1994 Econoline, F-150-350, Bronco F-Super Duty Service Manual, Page 13-01A-8, for the reset procedure.
5. Reinstall trim. Refer to the 1994 Econoline, F-150-350, Bronco F-Super Duty Service Manual, Page 01-05A-5, for the installation procedure.
6. Recheck fuse #8 and PSOM final verification.

PART NUMBER PART NAME
D4FZ-14A099-B 1/4" Scrolling (25 Ft. Roll)
D6AZ-19627-A Electrical Tape
D9ZZ-14526-D Fuse

OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper Warranty Coverage

OPERATION DESCRIPTION TIME
940912A Check And Repair Wiring 0.6 Hr.

[Steve83]

TSB 95-8-2 Wiper Motor
Publication Date: APRIL 24, 1995

FORD: 1986-94 TEMPO
1987-91 CROWN VICTORIA
1987-93 MUSTANG, TAURUS
1989-92 PROBE
1989-93 THUNDERBIRD
1991-94 ESCORT
LINCOLN-MERCURY: 1986-94 TOPAZ
1987-89 TOWN CAR
1987-91 GRAND MARQUIS
1987-93 SABLE
1988-94 CONTINENTAL
1989-93 COUGAR
1991-94 TRACER
1993 MARK VIII
LIGHT TRUCK: 1987-94 BRONCO, F SUPER DUTY, F-150-350 SERIES
MEDIUM/HEAVY TRUCK: 1980-94 L SERIES
1988-95 F SERIES

ISSUE: A revised service windshield wiper motor is now available, if the windshield wiper motor requires replacement.

ACTION: Replace the wiper motor with a revised wiper motor and use a Windshield Wiper Motor Service Kit to complete the installation. Refer to the Application Chart listed in this article for the proper application. Follow the detailed instructions included in the service kit.
1. Inspect the vehicle to see if the new Wiper Motor (-17508-) is already installed. If so, the latest level of wiring is already installed and the Wiper Motor Wiring Kit (-14A411-) is not required.
2. Install a new Wiper Motor Assembly. Refer to appropriate Service Manual for installation details.
3. Use the Wiper Motor Wiring Kit (-14A411-) if necessary to complete the installation. The Wiring Kit (-14A411-) consists of:
* One (1) Wiring and Connector Assembly
* Seven (7) 5/16" (8mm) Heat Shrink Tubing - 2" (51mm) long
* One (1) 37/63 (lead/tin) Solder 0.032" (0.80mm) diameter x 12" (305mm) long
* One (1) Adhesive Label
* Instruction Sheets
Not included in the kit is the Wiper Motor (-17508-).

Application Chart
Model Year Vehicle Wiper Motor Wiper Motor Wiring Kit
1987-91 Grand Marquis, Crown Victoria F5AZ-17508-B F4PZ-14A411-B
1987-93 Taurus, Sable F4DZ-17508-B F4PZ-14A411-B
1988-94 Continental F4DZ-17508-B F4PZ-14A411-B
1989-92 Thunderbird, Cougar F4SZ-17508-B F4PZ-14A411-C
1993 Thunderbird, Cougar F4SZ-17508-A F4PZ-14A411-C
1987-93 Mustang F5ZZ-17508-A F4PZ-14A411-C
1993 Mark VIII F4LY-17508-A F4PZ-14A411-B
1991-94 Escort, Tracer F5CZ-17508-A F4PZ-14A411-C
1986-94 Tempo, Topaz F43Z-17508-A F4PZ-14A411-C
1989-92 Probe F52Z-17508-A F4PZ-14A411-B
1987-89 Town Car F5VY-17508-A F4PZ-14A411-B
1987-94 F-150-350, Bronco, F-Super Duty F5HZ-17508-A F4PZ-14A411-C
1988-95 F-Series (Med/Heavy) Built Before 8/1/94 F5HZ-17508-A F4PZ-14A411-C
1980-92 L-Series Built through 11/26/91 F5HZ-17508-C F4PZ-14A411-C
1992-94 L-Series Built from 11/27/91 F5HZ-17508-B F4PZ-14A411-C

PART NUMBER PART NAME
F4PZ-14A411-B Wiring Kit
F4PZ-14A411-C Wiring Kit
F5AZ-17508-B Wiper Motor
F4DZ-17508-B Wiper Motor
F4SZ-17508-B Wiper Motor
F5ZZ-17508-A Wiper Motor
F4LY-17508-A Wiper Motor
F5HZ-17508-C Wiper Motor
F5HZ-17508-B Wiper Motor
F4SZ-17508-A Wiper Motor
F5CZ-17508-A Wiper Motor
F5VY-17508-A Wiper Motor
F52Z-17508-A Wiper Motor
F43Z-17508-A Wiper Motor
F5HZ-17508-A Wiper Motor
E92Z-6102316-A Retainer

OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 94-11-20, 95-4-6
WARRANTY STATUS: INFORMATION ONLY

[Steve83]

TSB 94-19-20 R-134a Charge
Publication Date: SEPTEMBER 21, 1994

LIGHT TRUCK: 1994-95 BRONCO, F-150-350 SERIES, F-47

ISSUE: Ford Climate Control Division has increased the refrigerant charge in the subject vehicles from 2 lbs. 1 oz. to 2 lbs. 6 ozs.

ACTION: When service to the A/C system is required, recharge the A/C system with 2 lbs. 6 oz. of R-134a. Make the necessary corrections to the 1994-95 Service Manuals, pages 12-00-35, 12-03A-58 for 1994 and 12-00-39, 12-03A-56 for 1995.
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.

OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY

[Steve83]

TSB 94-25-5 (Excerpt) Anti-Theft Service Tips
Publication Date: DECEMBER 12, 1994

...
1994 BRONCO
...

(B7) ISSUE: Water intrusion into the Right or Left Front Courtesy Lamp Switch (refer to EVTM) of the Anti-Theft System may cause inadvertent activation of the system.

ACTION: To correct this condition you should:
1. Remove the switch from the door.
2. Place a small amount of silicone sealant on the back of the connector where the wires exit the connector (enough sealant should be used to seal the connector and prevent further water intrusion).
3. Tape wrap the connector and about 1.5" (38mm) of the wires beyond the switch connector.
4. Reinstall the switch.
5. Verify the repair.

[Steve83]

TSB 95-13-2 Temperature Sender
Publication Date: JULY 3, 1995

ISSUE: Temperature Sender F1SZ-10884-A with a build date code prior to 2774 (277th day of 1994) should be purged from your inventory and returned to your facing PDC. These parts are being made obsolete because of an incorrect crimp during assembly. Installing these parts on a vehicle could result in early loss of temperature sender function.

ACTION: Remove and return the suspect parts from your dealership's inventory.

PART NUMBER PART NAME
F1SZ-10884-A Temperature Sender
OTHER APPLICABLE ARTICLES: 93-24-8
WARRANTY STATUS: INFORMATION ONLY
************************************************** ********************************
The code is stamped into the side of the hex. The format is the Julian date + the last digit of the year, so that's the 277th day of 1994. So 0085 is good; 1934 is bad; 3034 is good; 2765 is good; 3582 is bad. The sender should test at 74 Ohms cold; 9.7 Ohms hot. If you're having trouble with your temp gauge, try to read the date off the sender before any other diagnosis. A new sender from NAPA is under $10.

[Steve83]

TSB 93-4-6 Brake Shoes Grab
Publication Date: FEBRUARY 17, 1993

LIGHT TRUCK: 1987-93 BRONCO, F-150

ISSUE: The rear brakes may "grab" in the morning and/or after the vehicle sits for a long period of time. This condition may especially occur in cool and damp weather conditions. High humidity increases the friction of the brake linings.

ACTION: Replace the existing rear brake linings with new brake linings that are less sensitive to humidity/temperature conditions. Refer to the following service procedure.

SERVICE PROCEDURE
1. Remove the rear brake shoes. Refer to the appropriate model year Service Manual, Section 06-02, for the removal procedure.
2. Install new brake shoe and lining assembly Kit (F3UZ-2200-A). Refer to the appropriate model year Service Manual, Section 06-02, for the installation procedure.
3. Clean the brake assemblies and drums.
4. Adjust the brakes according to the Service Manual.

PART NUMBER PART NAME
F3UZ-2200-A Brake Shoe And Lining Assembly Kit

OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage For 1992/93 Models, Basic Warranty Coverage For All Other Models

OPERATION DESCRIPTION TIME
930406A Replace Rear Brake Linings 1.0 Hr.


CHECK THE TSB & FSA ALBUM in my signature link for additional articles.

[Chase Schule]

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