1999 Ford Technical Service Bulletins
Contents
1. 99 2 Publication Date JANUARY 26 1999 Tire Excessive Wear On One Front Tire Vehicles Built Through 12 1997 Equipped Article No With 14600 16000 18000 Or 20000 Ib Front Axle 99 2 f MEDIUM HEAVY TRUCK 1996 98 LOUISVILLE ISSUE There may be excessive wear of either the right front or left front tire on some vehicles equipped with a 14600 16000 18000 or 20000 lb front axle This may be caused by the front and or rear axle not being perpendicular to the frame ACTION Align front axle to be perpendicular to frame This should reduce tire scrub Refer to the following Service Procedure for details SERVICE PROCEDURE 1 2 6 7 Check total vehicle alignment On vehicles with tandem rear axles correct any misalignment as specified in the appropriate Louisville AeroMax Workshop Manual Section 204 00 or refer to TSB 98 21 15 for vehicles equipped with Hendrickson walking beam suspensions If front axle camber is out of specification replace Beam per Workshop Manual Section 204 01 Refer to Workshop Manual Section 204 00 for specification To align the front axle loosen the U bolts reposition the front axle and torque front axle U bolts to the torque specified below The front axle side to side variation to the rear axle should be not more than 3mm 1 8 or the set back should be less than 0 1 degree Reset toe to 0 8mm 1 32 3 4 U bolts are torqued to 339 407 N m 250 300 Ib ft 7 82. Alkaline Neutralizer directly onto a clean wash mitt Do not spray Alkaline Neutralizer on the painted surface Apply the product to the vehicle keeping the areas wet and lightly agitated for 5 to 7 minutes For vehicles with severe conditions work the product for up to 8 minutes Rinse the vehicle thoroughly with cold water Prepare Detail Wash by mixing 29 5 mL 1 ounce of Detail Wash to 3 7 L 1 gallon of water Shampoo the vehicle with Detail Wash using a clean wash mitt Rinse the vehicle with cold water and dry the vehicle completely NOTE DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE pH 7 AND MAY BE USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS Surface Correction Following Decontamination Neutralization 1 Visually inspect paint surface for evidence of removal of ferrous metal particles and water spots NOTE ACID RAIN DISCOLORING OR ETCHING WILL REQUIRE ADDITIONAL PROCEDURES DEPENDENT ON DEPTH OF DAMAGE POLISHING BUFFING COLOR SANDING OR IN EXTREME CASES REFINISHING Do Not Intermix Buffing Products Use only one manufacturer s products Always follow the manufacturer s product usage sequence Use the appropriate recommended pad at recommended buffing speeds as specified by the product manufacturer NOTE WHEN ATTEMPTING TO AFFECT A REPAIR BY BUFFING POLISHING OR COLOR SANDING DO NOT REMOVE AN EXCESS OF 0 3 MIL OF PAINT FILM OR REFINISHING WILL BE REQUIRED USE OF AN ELECTRONIC MIL
3. GAUGE ROTUNDA 164 R4025 IS HIGHLY RECOMMENDED TO INSURE CONTROL OF PAINT FILM REMOVAL Use a dual action sander with a Velcro backing plate and a foam pad to fine polish and remove any swirls created by a rotary buffer or pad Use an alcohol and water mixture 1 to 1 ratio to clean the buffed areas and to verify removal of scratches and swirls before application of the final polish FOAZ 19520 JA Acid Neutralizer 3 7 L 1 Gallon FOAZ 19520 FA Acid Neutralizer 18 9 15 Gallon FOAZ 19520 DA Alkaline Neutralizer 3 7 1 1 Gallon FOAZ 19520 GA Alkaline Neutralizer 18 9 15 Gallon FBAZ 1952 E A Detail Mash 3 7 L1 Gallon FB5AZ 19520 H4 Detail Wash 16 9 L 5 Gallon OTHER APPLICABLE ARTICLES NONE SUPERSEDES 97 21 3 WARRANTY STATUS Eligible Under The Provisions Of 12 Month 12 000 Mile Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME DEALER CODING Decontaminate And Surface Correction Aspire F 450 550 And Cargo Decontaminate And Surface Correction Escort 42 Ranger Regular Cab Probe Bronco And Aerostar Decontaminate And Surface Correct Escort Tracer Escort Tracer Wagon ContourMystique Mustang Convertible Convertible GT Taurus Sable Sedan Or Wagon 1996 1996 Villager And 1999 Cougar Decontaminate And Surface Correction F Series And 1996 97 Thunderbird Cougar Decontaminate And Surface Correction Ranger cuperCab Splash 150 250 Bed Regular Cab Flare Si
4. INDICATION OF DRAGGING OR BINDING OTHER ENGINE COMPARTMENT COMPONENTS HOSE WIRING ETC MUST NOT CONTACT ANY MOVING PART OF THE ACCELERATOR CONTROLS CAUTION THE INSTALLATION OF THE THROTTLE CABLE SERVICE KIT REQUIRES DRILLING NEW COMPONENT MOUNTING HOLES IN THE CAB FLOOR IT IS VERY IMPORTANT THAT ANY WIRING HARNESSES HOSES AFTERMARKET ACCESSORIES ETC THAT MAY INTERFERE WITH THE DRILLING OPERATION BE TEMPORARILY REPOSITIONED OR REMOVED THE FLOOR PAN AREA INSIDE AND OUTSIDE OF THE CAB MUST BE CHECKED TO MAKE SURE SUFFICIENT CLEARANCE IS OBTAINED The Throttle Cable Retrofit Kit F7HZ 9728 BA for F and B Series vehicles contains the following One 1 Engine Bracket One 1 Throttle Cable One 1 Engine Lever One 1 Throttle Pedal One 1 Dust Shield Three 3 1 4 Bolts Six 6 1 4 Nuts Six 6 1 4 Washers The Throttle Cable Retrofit Kit F8HZ 9728 BA for L Series vehicles contains the following One 1 Engine Bracket One 1 Throttle Cable One 1 Engine Lever One 1 Throttle Pedal One 1 Dust Shield Three 3 1 4 Bolts Seven 7 1 4 Nuts Seven 7 1 4 Washers Install a Cover Plate F7HZ 80113A52 AA over the hole in the cab floor previously utilized by the linkage mechanism The cover plate should be attached to the cab floor by four 4 Screws 55927 S2 PART NUMBER PART NAME F HZ 8728 B A Throttle Cable Retrofit Kit F And B Series FBHZ 87 28 B A Throttle
5. Series Service Manual Page 02 01 11 Item 3 for a representative illustration showing the crossmember installation Refer to the appropriate model year L Series Service Manual for proper installation of service parts and torque specifications NOTE ONE WASHER MUST BE INSTALLED UNDER THE BOLT HEAD AND ONE WASHER MUST BE INSTALLED UNDER THE NUT PART NUMBER PART NAME 5041 52 75 10 2 00 Bolt 16 Per Crassmember 34992 52 0 7510 Nut Per Crossmember 44582 52 0 75 1 44 Flatwasher 32 Per Crossmember OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME 90305A Use In Accordance To The Warranty And Policy Manual DEALER CODING BASIC PART CONDITION CODE OASIS CODES 304000 305000 390000 99 4 Publication Date FEBRUARY 19 1999 Cooling System Coolant Supply Tank Vent Hose Nipple Broken Vehicles Built Article No Through 12 17 1997 And With DDC Engine 99 4 4 MEDIUM HEAVY TRUCK 1996 98 AEROMAX LOUISVILLE ISSUE The radiator coolant supply tank vent hose nipple may break off at the tank connection Engine vent hose routing may allow the engine to pull on the tank nipple during engine articulation ACTION Replace the coolant supply tank and reroute the engine vent hose Refer to the following Service Procedure for details SERVICE PROCEDURE 1 Replace the coolant supply tank and associa
6. the touch Industrial Fallout o Water spots with ferrous metal are present and the surface is rough to the touch Acid Rain Etching e Surface will exhibit irregular discolored spotting e Dark colored vehicles may exhibit cloudy or graying spots where the acid has begun to etch the paint Extreme cases of etching will be visible and may be felt Decontamination Procedure Use Ford Acid Neutralizer Alkaline Neutralizer and Detail Wash to decontaminate and neutralize the paint surface Perform the procedure only on vehicle when the paint surface temperature is cool Follow the step by step procedure listed below to perform this service operation 1 Rinse off dust dirt and debris with cold water Flush liberally 2 Prepare Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket 3 Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the top of the vehicle working toward the side Keep the vehicle wet with solution lightly agitating for 5 to 7 minutes For vehicles with severe conditions work the product for up to 8 minutes NOTE USE A SEPARATE MITT FOR EACH PRODUCT DO NOT INTERMIX MITTS Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer Dry only the horizontal surfaces of the vehicle at this time Do not dry glass Alkaline Neutralizer is ready to use Do not mix with water Pour the contents into a dispenser squirt bottle Squirt
7. AIR ONLY TOP OF PARTICLE REMOVED CHEMICAL ETCH REMOVED PARTICLE AND CORROSIVE COMPOUNDS STILL PRESENT PARTICLES CORROSIVE COMPOUNDS CAUSING SEVERE DAMAGE TO PAINT S RESIN SYSTEM CLEARCOAT OR TOP COAT BASECOAT studies conducted have shown the use of Oxalic Acid ferrous metal removers actually contribute to further damage of the paint s resin system creating long term damage which may not be evident for months Additionally Oxalic Acid products may damage soft exterior trim aluminum trim and soften the paint The use of clay type products does not remove the entire ferrous particle or environmental contamination Clay removes only the top of the particle and stain generated by the contamination leaving the particle imbedded and the corrosive chemical compounds generated by the contamination in the paint system The particles and or chemical compounds are still present and they continue to generate damage Color sanding buffing or compounding the paint film to remove ferrous metal industrial fallout or acid rain damage may not remove the entire cause of the damage they treat only the symptom and not the cause The chemical compounds are still in the paint system and will continue to damage the paint Color sanding and buffing may result in excessive removal of clearcoat film Removal of OEM clearcoat in excess of 0 3 mil may contribute to premature clearcoat failure and is not recommended THE DECONTAMINATION PROCED
8. CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM OR PAINTED SURFACES NOTE THE PRODUCTS USED TO REMOVE SURFACE CONTAMINATION FROM PAINT ARE DESIGNED FOR VEHICLES WHICH HAVE EXPERIENCED EXPOSURE FOR LESS THAN 120 DAYS VEHICLES THAT EXCEED 120 DAYS OF EXPOSURE MAY REQUIRE THE PROCEDURE BE REPEATED TO RESOLVE THE CONCERN ONCE THIS PROCEDURE IS COMPLETED IT MAY BE NECESSARY TO PERFORM POLISHING OR REFINISHING PROCEDURES AFTER VEHICLE INSPECTION IDENTIFICATION Ferrous metal particles hot iron dust are generated by manufacturing facilities rail shipments etc These particles mechanically bond to a vehicle s painted surfaces Moisture and temperature combine with particles to create a chemical reaction This reaction creates an acid causing the iron to corrode and enter the paint surface Industrial fallout and acid rain generate corrosive compounds that fall on the vehicle s painted surfaces When subjected to moisture and temperature chemical compounds are created that etch the paint surface To assist in identifying surface contamination use a Tandy Radio Shack 63 851 30x lighted magnifier Concern Description Ferrous Metal e Light Colored Vehicles Small orange stains the size of mechanical pencil lead The surface is rough to the touch e Dark Colored Vehicles Small white or silver appearing dots with a rainbow ring around the dot The surface is rough to
9. Cable Retrofit Kit L Series 1545244 Cover Plate 55927 52 acrew 0 10x0 50 Pan OTHER APPLICABLE ARTICLES NONE SUPERSEDES 97 20 22 WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME 9914134 Install Throttle Cable System 1 2 Hrs 9474756 Extra Time To Install Cover Plate 0 1 Hr DEALER CODING BASIC PART NO CONDITION CODE 9A710 OASIS CODES 497000 703000 703100 703200 703300
10. HICH IS CURRENTLY MOUNTED ONTO THE THROTTLE PEDAL ASSEMBLY THE NEW THROTTLE PEDAL ASSEMBLY DOES NOT HAVE A PROVISION FOR MOUNTING THIS SENSOR ANFD1060 160 HP ENGINE WITH THE BOSCH ROTARY TYPE FUEL INJECTION PUMP NOTE ON 1992 AND 1993 F B AND L SERIES VEHICLES SAFETY RECALL 93572 MUST BE PERFORMED FIRST BY AN AUTHORIZED FORD DEALER BEFORE THE NEW THROTTLE CABLE SYSTEM CAN BE INSTALLED THIS CABLE SYSTEM IS NOT COMPATIBLE WITH THE ORIGINAL THROTTLE RETURN SPRING SYSTEM NOTE FOR L SERIES VEHICLES ONLY IF THE VEHICLE IS EQUIPPED WITH AN FD1460 ENGINE AND OPTIONAL ETHER COLD START SYSTEM THEN IT WILL BE NECESSARY TO RELOCATE BOTH THE ETHER BOTTLE AND WINDSHIELD WASHER FLUID RESERVOIR THESE COMPONENTS WILL HAVE TO BE RELOCATED TO PROVIDE THE NECESSARY CLEARANCE FOR THE NEW THROTTLE CABLE SYSTEM THE NEW POSITION OF THESE COMPONENTS WILL THEN BE THE SAME AS THAT ON VEHICLES EQUIPPED WITH THE FD1060 ENGINE INFORMATION REGARDING RELOCATION OF THE ETHER START SYSTEM AND WASHER FLUID RESERVOIR IS PROVIDED IN THE SERVICE KIT CAUTION ONCE THE NEW THROTTLE CABLE SYSTEM IS INSTALLED THE OPERATION OF THE ENTIRE THROTTLE SYSTEM MUST BE THOROUGHLY CHECKED TO ENSURE PROPER OPERATION WITH THE ENGINE RUNNING DEPRESS THE ACCELERATOR PEDAL TO ITS FULL EXTENT THEN SLOWLY RELEASE THE PEDAL SLOWLY RELEASE MEANS MOVEMENT NO FASTER THAN APPROXIMATELY 2 SECONDS PER INCH THE THROTTLE PEDAL MUST RETURN COMPLETELY TO IDLE POSITION WITHOUT ANY
11. U bolts are torqued to 542 651 N m 400 480 Ib ft The front axle U bolts must be checked and tightened again after 800 1600 km 500 1000 miles PART HUMBER PART NAME FSH2 3010 H Front Axle Beam 14 FBHz 3U10 AB Front Axle l Beam 16 20K OTHER APPLICABLE ARTICLES 98 21 15 WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME DEALER CODING BASIC PART CONDITION CODE 3010 30 OASIS CODES 303000 306000 390000 99 3 Publication Date FEBRUARY 15 1999 Article No 99 3 8 Suspension Rear Crossmember Loose Or Cracked Vehicles Built Through 11 1996 MEDIUM HEAVY TRUCK 1992 97 L SERIES ISSUE Loose or cracked rear Suspension crossmember s may be evident on some vehicles This may be caused by insufficient clamping force produced by the upper and lower bolts that attach crossmember s to the frame mounted gusset ACTION e crossmember is cracked it requires replacement e If the crossmember is loose remove torque rod and existing attaching hardware Enlarge the holes the crossmember and gusset to 20 50 21 00mm 0 807 0 827 diameter Install the 0 75 diameter hardware and torque the nuts to 350 400 N m 260 300 Ib ft If the holes in the crossmember or the gusset are elongated larger than 19mm 0 75 the crossmember requires replacement part number is located on the flange of the crossmember Refer to the 1996 L
12. URE DIRECTED IN THIS BULLETIN MUST BE PERFORMED BEFORE ANY BUFFING POLISHING COLOR SANDING OR REFINISHING I3 ATTEMPTED TB 4187 B Figure 1 Article 99 12 10 99 14 Publication Date JULY 6 1999 Article No Vibration Throttle Pedal Vibration Or Buzz 99 14 13 FORD 1992 99 F amp B SERIES 1993 97 L SERIES This TSB article is being republished in its entirety to add model years and service parts ISSUE A vibration or buzz may be experienced through the throttle pedal on some vehicles equipped with an FD1060 or FD1460 midrange Diesel engine This may be caused by engine vibrations being transmitted up the mechanical linkage to the throttle pedal ACTION Replace the current mechanical linkage throttle system with a revised throttle cable system The throttle cable system does not transmit engine vibrations to the throttle pedal Refer to the following text for details The complete installation procedure for the revised throttle cable system is provided in the Service Kit NOTE THE NEW THROTTLE CABLE SYSTEM PROVIDED IN THIS TSB ARTICLE CAN BE USED ON F B AND L SERIES VEHICLES EQUIPPED WITH AN FD1060 OR FD1460 ENGINE WITH BOSCH INLINE P TYPE FUEL INJECTION PUMP AMANUAL OR ALLISON MT AT AUTOMATIC TRANSMISSIONBUT CANNOT BE USED ON B AND L SERIES VEHICLES EQUIPPED WITH AN ALLISON MD ELECTRONIC AUTOMATIC TRANSMISSION THE MD TRANSMISSION REQUIRES AN ELECTRONIC THROTTLE POSITION SENSOR W
13. de Regular Cab F 50 350 50 Bed Regular Cab 450 550 Crew Cab And Louisville Aerohlax Decontaminate And Surface Correction Mustang Coupe Coupe GT Continental Mark Vill Ranger splash cuperCab Explorer 2 And 1999 illaqer Decontaminate And Surface Correction F 150 250 BFt Bed SuperCab BFt Bed Regular Cab Flare Side And F 250 350 SD Bed SuperCab BFt Regular Cab Decontaminate And Surface Correction Crown Victoriafiorand Marquis Town Car Windstar Explorer 4 Door And Mountaineer Decontaminate And Surface Correction F 150 250 Bed SuperCab F 250 350 SD Bed Crew Bed SuperCab BFt Bed Crew Cab And Expedition Mavigator Decontaminate And Surface Correction Econoline Wagon Magon Super Decontaminate And Surface Correction Econoline Cargo Decontaminate And Surface Correction Econoline Cargo Super BASIC PART NO CONDITION CODE ENTRE OASIS CODES 106000 190000 INDUSTRIAL FALLOUT is a general term used to identify Rail Dust Brake Dust Ferrous Metal Alkaline Crystalline Deposits Water Spots Acid Rain and other types of Environmental Contamination 15T STAGE DAMAGE 2ND STAGE DAMAGE CONTAMINATION HAS PENETRATED PAINT FILM DISCOLORATION AND CORROSIVES SPREADING IRON ACID RAIN PARTICLE ENTERING STAINING AND PAINT CORRODING SURFACE CLEARCOAT TOP COAT BASECOAT SRD STAGE DAMAGE INCORRECT REP
14. ne Access Door Spring OTHER APPLICABLE ARTICLES 98 20 23 WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME 4406014 Replace Spring 0 3 Hr DEALER CODING BASIC PART NO CONDITION CODE 42430 OASIS CODES 108000 111000 112000 190000 99 10 Publication Date MAY 14 1999 Body High Floor Heat During Idle With PTO In Operation Vehicles With CAT 3306 Article No Engine 99 10 2 MEDIUM HEAVY TRUCK 1997 98 LOUISVILLE ISSUE High floor heat may arise during idle with PTO in operation During PTO operation with the vehicle stationary in cab temperatures can cause driver or passenger discomfort ACTION Install a thermal heat barrier shield under the floor trim mats to provide additional insulation Refer to the following text for details Use Heat Barrier LF 198 that can be obtained from Lydall Westex 248 952 5570 8 00am 5 00pm EST and install with aluminum side down Material required per cab is two 2 1 8 square meter 6 square feet sheets Cut to fit using floor trim as guide Assure sufficient clearance around brake pedal clutch pedal and accelerator so that operation of these controls is not affected NOTE LIFT FLOOR MAT TRIM UP BEFORE PLACING HEAT BARRIER SHIELD DOWN THEN COVER WITH MAT TRIM OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS INFORMATION ONLY OASIS CODES 101000 107000 111000 99 12 Publication Date JUNE 7 1999 Pain
15. t Iron Particle Removal Industrial Fallout Acid Rain Neutralization Article No 99 12 10 Paint Rough Texture Ferrous Metal Contamination Acid Rain Discoloration Or Etching FORD 1996 97 ASPIRE PROBE THUNDERBIRD 1996 99 CONTOUR CROWN VICTORIA ESCORT MUSTANG TAURUS LINCOLN MERCURY 1996 97 COUGAR 1996 98 MARK VIII 1996 99 CONTINENTAL GRAND MARQUIS MYSTIQUE SABLE TOWN CAR TRACER 1999 COUGAR LIGHT TRUCK 1996 BRONCO 1996 97 AEROSTAR F SUPER DUTY F 250 HD F 350 1996 99 ECONOLINE EXPLORER F 150 F 250 LD RANGER VILLAGER WINDSTAR 1997 99 EXPEDITION MOUNTAINEER 1998 99 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM HEAVY TRUCK 1996 97 CARGO SERIES 1996 98 AEROMAX F SERIES LOUISVILLE This TSB article is being republished in its entirety to add vehicles and model years and to revise the procedure to use Ford brand service parts ISSUE Ford Motor Company has released a private labeled material to be used for iron particle acid rain service repairs ACTION To remove these particles contaminates use ONLY the following products and procedure No polishing compounding color sanding or repainting should be done before this procedure is performed This procedure uses products that are acidic alkaline and neutral and must be properly mixed and used in their specific order Refer to the following Service Procedure for details SERVICE PROCEDURE NOTE ANY CHANGES TO THIS PROCEDURE WILL
16. ted hardware Refer to the appropriate Louisville AeroMax Workshop Manual Section 303 03 or Service Manual Section 03 03 2 Loosen the engine clip as necessary where the engine vent hose line is routed through and add 25 4mm 1 slack between the hose clip and the coolant tank nipple The vent hose is sufficiently long to allow the 25 4mm 1 slack Refer to Figure 1 3 Retighten engine clip to retain the vent hose PART NUMBER PART NAME FEBHZ aC3B2 A Js Or vent Hose Or Silicone Bulk Hose Or XCAZ BC3B2 F Coolant Tank Engine Clip 1 00 Wrap Around Clip Bolt 516 10x0 621 OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME 99041014 4 Replace Coolant Tank And Reroute Hose Hr DEALER CODING BASIC PART CONDITION CODE OASIS CODES 206000 402000 FITTING NIPPLE RADIATOR SUPPLY TANK GUB ENGINE VENT HOSE 5844 Figure 1 Article 99 4 4 99 6 Publication Date MARCH 19 1999 Article No 99 6 1 Door Hinge Ready Line Door Hinge Spring Broken MEDIUM HEAVY TRUCK 1996 98 AEROMAX LOUISVILLE ISSUE The Ready Line Access Door Spring XC4Z MF062A AA may be broken ACTION Replace the spring with a revised Spring XC4Z MFO62A AB PART NUMBER PART NAME ACAZ MF BZA AB Freightliner Sterling Ready Li
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