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1995 Ford Technical Service Bulletins

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1. N PT suo Bos state 2675 Fousson oGusB FT Indigo Blue Metallic CIC A 89670 FAJKU B9683 FAGEDY 2611 20644 DY N HB so eors roues 15160 HE ee micca m es tign Opal metae N we sic Bara rawe see Fouess aaisa 22986 89674 FA9SKT 26162 Fosse 9038 54962 Dark N ND soso Fasano 55 amies oche 25163 Hecker Figure 2 Article 95 23 1 1996 FORD MEDIUM AND HEAVY TRUCK PAINT CODES Else al a an o Bo Colar Acme Color Nama Sikkens Sherwin Willlams Gitu Autocolor Standox 17248 vc so Foos oma vc Dessen ie De Timer 02260 er rousse 2078 17688 BW 50044 Bahama Blue CO MR 2281 8240 FASO 03081 zs Fou soo4 sses Leone we neu Fou 5466 wwe sss oc 56814_ Candy Apple Red CO EU 8 Sm xm Fou 5681 Hagg 9 EU Darren 25150 Bg _ aee 132 rou sese oseso az casta co aa 38163 1148
2. TB 3248 B Figure 4 Article 95 23 15 NOTE ISOLATORS WILL NOT PROVIDE PROPER DAMPING WITHOUT THE VOIDS LOCATED ON THE TOP AND BOTTOM 9 Reinstall the hardware 10 Check that engine idle speed is set between 700 750 rpms If it is not refer to the Powertrain Control Emissions Diagnosis Manual Section 19A for the proper idle setting procedures OTHER APPLICABLE ARTICLES NONE SUPERSEDES 93 25 19 WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 497000 499000 703000 703100 95 23 Publication Date NOVEMBER 20 1995 Noise Metal Scraping During Turn Vehicles With 12 To 14 Liter Engine Article No Vibration During Turn Vehicles With 12 To 14 Liter Engine 95 23 16 MEDIUM HEAVY TRUCK 1990 96 L SERIES This TSB is being republished in its entirety to include the 1994 96 model year vehicles ISSUE A loud metal scraping noise and vibration may be heard and felt in the cab during left or right hand turns This noise vibration may be caused by the front engine mount spacers contacting the front engine support crossmember This condition has been reported only on L 9000 Series vehicles with 12 to 14 liter engines and most frequently on the Aeromax 106 and Aeromax 120 models but may occur on other models as well ACTION Widen the front engine mount spacer holes in the front engine crossmember Refer to the following Service Proce
3. Fou sse 2 50732 ke apis C C co RENE HE HN NE use CO EY ass 22006 Foues tawe 37237 Er uf rc um 9162 4530 22009 200586 taman oseo PC ED ole ete st es 21661 Fousser 14678 ossa Vis CIC ec Bares Fago 46747 22008 Fou eeas 2nase ar Gc m misma 00 mi 257 4774 zais Foues cares OM 66954 Medium Sonora CO 27518 FASSDN 4773 2318 200465 otaga apis ON Nimbus a oo zi sss mee arme Fossa erma 7083 7 Ak BasecoalClaarcoat TB 4201 B Figure 3 Article 95 23 1996 ASPIRE PAINT CODES Mastin Senabi kzo pe Ici DuPont Sikkens Sherwin Williama Glasurit Autocolor Hund Code Le sr pem Dem cem ac mee e m 10715 we Faama aeo roue soos MB e pne mec mes mer 2 es 739 rie 472 oo Fouso 24688 3887 Es m Ps New Crystal wie CO co OO co n 942 FA9 amp FR 52725 26221 roura 39190 FA 21844 sera 2922 Fours
4. 374374 5101 5 Water Temperature Sender e Figure 2 Article 95 20 12 1 2 Install the bushing into the tube assembly Install the new tee 374374 5101 into the bushing 3 Install the water temperature sender into the side port of the new tee 4 Install connector into the top port of the new tee 5 Install the clamp and hose onto the connector and torque the clamp to 3 4 4 5 N m 30 40 Ib in 6 Install the electrical connector onto the water temperature sender 7 Refill the cooling system following the procedure the 1995 F B or L Series Powertrain Drivetrain Service Manual Section 03 03 OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 204000 206000 402000 Bulletin Contents TSB Article 95 21 2 has been superseded by Article 98 5A 13 95 21 Publication Date OCTOBER 23 1995 Air Cleaner Revised Air Cleaner Inlet Duct Vehicles Equipped With Caterpillar 3306 Article No Engine 95 21 10 MEDIUM HEAVY TRUCK 1990 95 L SERIES ISSUE The air cleaner air duct may come into contact with the hood In rare situations the air duct could rub a groove into the hood ACTION Replace the air duct with the revised air duct which will allow for added clearance between the hood and duct The revised duct will reduce the possibility of the air duct rubbing on the hood Refer to the appr
5. threads of the bolts should be wiped clean removing any oil or debris and excess build up of old Loctite Bolts do not have to be cleaned down to the metal Apply Loctite 242 or 262 Loctite 262 is a permanent type thread sealer on the bolt threads e Use a torque wrench and torque to 35 N m 26 lb ft Old New New Cummins Ford Service Cummins Part No Part No Part No Gear Housing F3HZ 6019 J 3916380 F3HZ 6019 J 3926518 Front Cover F3HZ 6019 K 3916193 F2HZ 6019 AA 3926847 Gasket Gear F3HZ 6020 E 3281721 F2HZ 6020 AA 3929253 Housing to Block Gasket Front F3HZ 6020 F 3917780 F6AZ 19562 AA Cover to Gear Sur Housing Gear Housing 3900630 CF 3926846 CF 3926846 Botts Short Gear Housing 3900633 CF 3926863 CF 3926863 Bolts Long Also available as Loctite 5900 GEAR HOUSING 7B 4190 A Figure 3 Article 95 15 17 OTHER APPLICABLE ARTICLES NONE SUPERSEDES 95 3 24 WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 401000 499000 Bulletin Contents TSB Article 95 15 18 has been superseded by Article 95 19 18 95 16 Publication Date AUGUST 14 1995 Brakes Front Front Axle Shudder Vibration When Brakes Are Applied Vehicles Equipped With 14 600 16 000 And 18 000 Lb Front Axle Assemblies Equipped With Rockwell 16 5 X 6 Inch Brake Assemblies Article No Vibration Shudder Fro
6. Pa Martin Senour Color Alan Acme BASF Kl Spies Code Sikkens Sherwin Witiams RM Glasurit Autocolor Hecker Standox amoa rouma emp ost 24065 FDUPUB 2 m uem EDU _ 7XHoB 61434 wg pies in em e ee NEN oe L ues p aee d BasecoatClearcoat Tri Coat Tinted Clearcoat TB 4418 A Figure 4 Article 95 23 1 ACTION Paint should be available in either enamel or urethane from the manufacturers To get the color match use of either Factory Pack or Intermix is acceptable OTHER APPLICABLE ARTICLES 92 20 1 93 24 4 SUPERSEDES 95 7 2 WARRANTY STATUS INFORMATION ONLY OASIS CODES 106000 95 23 Publication Date NOVEMBER 20 1995 Engine Excessive Vibration At Low Engine RPM Article No Vibration Engine Excessive Vibration Noise At Low Engine RPM 95 23 15 MEDIUM HEAVY TRUCK 1992 93 CARGO SERIES F amp B SERIES L SERIES This TSB is being republished in its entirety to include a NOTE after Step 8 and to include Step 10 ISSUE The subject vehicles may exhibit excessive engine noise vibration harshness at low engine rpm This may be caused by the engine mounts ACTION Install improved engine mounts now available as a service kit Refer to the following procedure and to the Instruction Sheet included in each kit for service details
7. Normal condition in extremely hot weather or at slow vehicle speeds in warm weather Faulty temperature gauge A C system overcharged or condenser covered with debris Refrigerant pressure switch may be faulty Fan temperature switch is faulty if fan engages at low engine temperature and A C is off Airline may be leaking Horton Evans air on fan drives Wiring may be shorted and or fuses circuit breakers blown Air solenoid may be faulty Test air solenoid valve by shorting across the terminals of the temperature switch to energize the air solencid valve and to activate the fan drive Replace faulty component Check air conditioning system Replace pressure switch if necessary Defective overtemp waming Replace overtemp waming switch switch a Check solenoid plumbing b Replumb solenoid valve Replace overtemp warning switch Move overtemp warning switch as close to the fan temperature switch as possible Replace temperature gauge Replace fan temperature switch Replace temperature gauge or sender Check A C system Replace pressure switch if necessary Replace fan temperature Switch Check air lines Fix where necessary Check wiring fuses and circuit breakers If solenoid does not activate replace solenoid TB 3275 B Figure 2 Article 95 25 14 a Manual override switch is ON
8. Part ltem Number Descriptian Oty AIR BRAKE REF Locking 10 1 5 20 109 2 Washer M10x21 0x2 25 Hardan Bolt M10x150x50 Hex P C 10 8 Brackat Compressor Mounting Bolt M10x150x35 Hex P C 9 8 N601315 S2 FA4HZ 2WB96 A N605802 S100 3 4 5 5 FRONT OF 4 VEHICLE TB 4223 A Figure 6 Article 95 15 17 9 10 11 12 Install the compressor rear support mounting brackets using Loctite 242 Coat the bolts removed or use new bolts shown in Figure 6 Only install the bolts finger tight The total alignment of the brackets is critical The mounting holes in the brackets allow for some movement for alignment Align the brackets before tightening the bolts to ensure there are no binds in the brackets compressor Torque the bolts to 61 N m 45 Ib ft If the power steering pump has been removed use a new power steering pump gasket FAHZ 3K506 C and install pump on the back of the compressor Use Loctite 242 to coat each bolt and torque to 61 N m 45 Ib ft Install the front cover seal F3HZ 6700 B as outlined in the appropriate Service Manual Section 03A into the Sunrise Front Engine Cover Using Loctite 5900 or Cummins Three Bond Sealer 3823494 place a 4mm bead along the entire flange of the gear cover Refer to Figure 2 Figure 2 Article 95 15 17 13 Follow the grooves in the flange and circle each of the bolt holes with
9. 96 6262 Dark ChesmutMetaic cO ce 4 pease FASOCE 18146 204 6262 aisan sre 62844 School Bus Yelow CO BY perma sog FDUG2OA waso 160135 ey exa CurrantRed Sold co tc 4161 Beo 39007 19051 FDU xS was 38868 EC Diamond White aia CO za seem ese asara 19073 Fouegar vaso 14088 za 63 Ebony Sace a co UA gro Fasoua aras 16183 Foues zeger uva Lem mersa mw um nen em aee mue on HE 64154 Crystal Blus CO MD 4214 200m ruens case 9250 FOIE TEE IRE seta rages amer 2008 Prron 98255 EG 64704 Vermilion Solid CC e 19079 Tere saooa Es amp 70A Royal Be CC A 24045 spsee sorso KM ema ee 64874 IN ses FaseDa zawo Four tapes sers oA 6sora Medium Opel GC A CO aun FA92 WC E RETIA EXE 43838 21169 00 5506 65544 Medium Opal Metalic m FAGE WD 48950 Foues 72257 wo EHE UTI CER ECOLE CNET ORC TRUE a Fou W6556 5AGIB 9150 Mecum Lapis tale Lo ie
10. Faura mo O 297 ebuszoa etrap 53725 67044 Bright Sapphire Mer N JA 492 3957 FAEJA 503 25081 40950 go Benya N FJ 2578 mosa Dark Berry CC FF 4990 sea rare soms 2504 Fouer ewe aosa FE 6707A Medium Beny MeL N ro 88509 5 2573 fouer 67084 LghtWiow Met CIC A SL ases seo Faasse soso 2574 046708 61085 67094 Deep Ins N Ge aeo Faster Fou s70a erwas 40207 GP 712 MatumOmphteCC A N TA 4 85 soan 26079 722 TR ea Pumice Sold N bo 499 59 soaa 2505 eouaria ewvig 72204 00 715 Medum WiwMet CC A N SH 40M FasssH _ 50300 25075 FDuer s 61084 3H Ultra Violet Metalic CIC A GN 4979 sesta rAosGN 25087 jr epar ad E ME 4981 89515 50307 74468 60 SieFosCCA N Ts 4o rasas 592 osoa eouerzo ewyas 723 15 Colonial While GIG N Fouer ewese 111 2 8750_ Cypress Frost oa N BF sos Bose Faer 8529 zs rouezo 206 BF emo Dark Cypress Gold A N BB soge 5128 Fnuszs2 7448 zu Bright Tang
11. Figure 5 Article 95 15 16 b Three piece tang type wheel nut system Figures 6 and 8 THREE PIECE TANG TYPE WHEEL NUT SYSTEM INNER NUT P N 11249 s OUTER NUT P N 11249 ns TANG TYPE LOCKWASHER P N 11249 0 123 3 12 THICK TB 4309 A Figure 6 Article 95 15 16 SPINDLE BEND TANGS ONE 1 OVER INNER NUT AND ONE 1 OVER OUTER NUT INNER NUT LOCKING WASHER OUTER NUT Figure 8 Article 95 15 16 Four piece tang dowel type wheel nut system Figures 7 and 9 FOUR PIECE TANG DOWEL TYPE WHEEL NUT SYSTEM INNER NUT P N 119882 DOWEL TYPE LOCKWASHER P N 119883 OUTER NUT P N 119881 DOWEL PIN TANG TYPE LOCKWASHER P N 129132 0 0478 1 21mm THICK TB 4310 A Figure 7 Article 95 15 16 SPINDLE INNER NUT BEND TWO 2 TANGS OVER OUTER NUT LOCKING WASHER OUTER NUT TB 4312 A Figure 9 Article 95 15 16 2 5 WARNING DO NOT MIX SPINDLE NUTS AND LOCKWASHERS FROM DIFFERENT SYSTEMS MIXING SPINDLE NUTS AND LOCKWASHERS MAY CAUSE WHEEL SEPARATION NOTE THE LOCKWASHER FOR A FOUR PIECE TANG DOWEL TYPE WHEEL NUT SYSTEM IS THINNER THAN THE LOCKWASHER FOR A THREE PIECE TANG TYPE WHEEL NUT SYSTEM AND IS NOT DESIGNED TO BEAR AGAINST THE INNER NUT Inspect the spindle and nut threads for corrosion and clean thoroughly or replace as required NOTE PROPER ASSEMBLY AND ADJUSTMENT IS NOT POSSIBLE IF THE SPINDLE NUT OR THREADS
12. a If the fuses blow whenever the ignition is turned on the problem is most likely related to a fault in the wiring If the fuses blow only when the fan engages the fault is probably associated with the solenoid valve Check wiring and fix where necessary Use an ohmmeter to check for a shorted solenoid coil the coil resistance should be greater than 14 ohms If shorted replace air solenoid valve TB 3307 B Figure 4 Article 95 25 14 OTHER APPLICABLE ARTICLES NONE SUPERSEDES 93 21 21 WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 402000 95 25 Publication Date DECEMBER 18 1995 Cooling System Heater Supply Tube Leaking Coolant Vehicles With Detroit Diesel Article No Series 60 Engine 95 25 15 MEDIUM HEAVY TRUCK 1995 L SERIES ISSUE The heater supply tube may leak on some vehicles This may be due to spot weld separation at the heater supply tube stand off bracket causing a hole in the supply tube ACTION Replace and re route the heater supply tube with a revised design part Refer to the following Service Procedure for details SERVICE PROCEDURE 1 Drain the engine coolant 2 Remove the heater supply return tube assembly Figure 1 Item 1 Remove the heater supply shutoff valve and bushing from the oil cooler Figure 1 Items 2 and 3 in View A Retain the valve for reuse discard the bushing ee
13. ISSUE There may be concerns of reduced operating range of the Two Way Radio on some vehicles equipped with Allison World Transmissions MD and HD Series This may be due to Radio Frequency Interference RFI The Allison electronic control system complies with all FCC and other guidelines regarding radio frequency emissions ACTION Refer to the following guidelines when installing a land mobile radio into a vehicle These guidelines are intended to supplement but not to be used in place of detailed instructions supplied by the manufacturer of the land radio being installed Most concerns of may be eliminated when these installation guidelines are followed GENERAL GUIDELINES TRANSMITTER LOCATION 1 The transreceiver for remote radios should be located away from other electronic devices and as near to the vehicle body side as possible 2 One piece transreceivers should be mounted under the instrument panel where they will not interfere with the vehicle s controls or passenger movement ANTENNA INSTALLATION Each vehicle model and body style reacts to radio frequency differently It is suggested that a magnetic mount antenna be used to check the proposed antenna mounting location for unwanted effects before the antenna is permanently installed Antenna location is a major factor in these effects ANTENNA CABLE ROUTING 1 High quality coax at least 9596 shield coverage should always be used and located away from all ele
14. This may be caused by the convoluted tubing not fully enclosing the Fuel Shutdown Solenoid wiring harness allowing it to rub on the fuel lines ACTION Install a stand off bracket and secure the wiring to the bracket to move the wiring away from the fuel lines Refer to the Instruction Sheet I S 6672 included in the kit and the following for service details 1 Install the stand off bracket using the M12 bolt and washer as shown in Figure 1 Torque the bolt to 44 70 lb ft 60 95 N m FOHT 8K157 BA E lu x o lt oc 7 N807871 52 BOLT 29 8 H 45 a d D d ER 28 52 ES CYLINDER HEAD TB 4094 A VIEW A Figure 1 Article 95 11 15 2 Install the retaining clip around the Fuel Shutdown Solenoid wire and secure to the Stand off Bracket as shown in Figure 1 Ensure that the wiring has adequate clearance from the injector lines Torque the 5 16 bolt to 12 17 Ib ft 16 23 N m The Stand off Bracket Kit F5HZ 8K157 CA includes the following One 1 Bracket Two 2 Bolts One 1 Washer One 1 Nut with Washer One 1 Instruction Sheet I S 6672 OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage And Emissions Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 203000 404000 95 11 Publication Date JUNE 5 1995 Climate Control Revised Blower Motor Switch Vehicles Equipped With City Deli
15. 1987 95 CARGO SERIES F amp B SERIES L SERIES ISSUE Some trucks may show irregular front axle tire wear and reduced tire life This can be due to improper total vehicle alignment excessive front axle toe in excessive bearing adjustment wrong tires for application or other see appropriate vehicle Service Manual Page 04 04 8 ACTION Revised front axle assemblies have been designed with symmetrical camber specifications which may reduce tire wear Refer to the following procedure for service details NOTE IT IS THE CUSTOMERS RESPONSIBILITY TO ENSURE TOE IN AND TOTAL VEHICLE ALIGNMENT SPECIFICATIONS ARE CORRECT SERVICE PROCEDURE For vehicles exhibiting this concern check the part number of the axle This number can be found on the center of the axle on the web Refer to the following chart If the axle part number falls in the old part number column the camber needs to be checked older axle assemblies may meet the new camber specifications The revised specification is 3 8 3 8 If the camber does not fall into the specification the axle assembly needs replacement Always use new original equipment U bolts if replacing axle Refer to the following chart for correct replacement axle Refer to the appropriate vehicle Service Manual for axle replacement procedure and correct torque values NOTE ADVISE CUSTOMER THAT IF THE AXLE IS REPLACED THE FRONT AXLE U BOLTS NEED TO BE RETORQUED AFTER THE FIRST 1 000 MILES 1 600
16. E 9 m oM muy 2 N ns lt AY RL j m eu Description Heater Supply Retum Tube Assembly Kem Shutoff Valve Bushing FRONT OF VEHICLE 2 4376 Figure 1 Article 95 25 15 Locate the 3 4 pipe plug near the center of the cylinder head just behind the thermostat housing Figure 2 Remove the plug and retain for reuse Install the 389275 S101 or equivalent 1 2 internal 3 4 external 45 degree pipe elbow into the cylinder head Index the fitting so the opening points forward SEE VIEW A HEATER SUPPLY RETURN TUBE ASSEMBLY SHUTOFF VALVE din o 53 ES 4387 Figure 2 Article 95 25 15 4 Remove the hose connector from the water shutoff valve removed earlier Install a 391140 S101 or equivalent straight connector 5 8 hose x 1 2 14 external pipe on the valve and install the valve into the elbow installed in Step 3 Index the valve Figure 2 View A View A is looking down at the valve 5 Install the pipe plug removed from the cylinder Step 3 into the oil cooler where the shutoff valve was previously located 6 Install the new heater return line on the engine Install hoses and hose clamps torque clamps from 3 4 4 5 N m 30 40 Ib in Torque the 5 16 bolt which attaches the heater tube stand off bracket from 16 3 23 N m 12 17 Ib ft Install the bolt removed from t
17. E Frost CIC co CA eo 4829 2 4881 Dark Lapis Metallic 738 BasecoatiCdearcoat TriCoat Tinted Clearcoal mem ai SPFoB 70652 5PsrB 60479 46747 EIN ETA 89354 FaesrC area 2 RN 24947 20 6638 59588 m RIT IN INE um Bos Fagre 20000 Foue 5007 FE 2408 20046653 dott d Bo447 WA 484518 er 5 9 BEE 29448 48452 SPESG 47486 Fou os7s 1048 Bz pases Fouse aero m Figure 1 Article 95 23 1996 FORD CAR AND LIGHT TRUCK PAINT CODES No Color Name Code 6688 Laser Red Tint THC kA 4545 A846 Martin Senour ee teen Sikkens Stenwln Wilame RM Glasurit paa 49 E9403 BasacoatClearcoat Tr Cost Tinted Clearcoal Autecalor 782 6689 Bronze co op 4766 sexo FAsxDP ara 2 200688 swrse 20222 Midnight Red Met Cic A N en 493 FASEN sos ase FoUecs7 skaza xor EN 700 Graphite Night Mist Cc zu soma 2989 Fouero erase 72m ZU 6703 Venetin Bue Met CIC A CO TA
18. NOTE TURN THE SPOT FACING TOOL BY HAND ONLY THE USE OF A POWER SOURCE WILL DAMAGE THE TOOL BODY AND CUTTING EDGES THIS TOOL IS DESIGNED TO REMOVE RAISED AND OR GROOVED MATERIAL ONLY NOT TO MACHINE THE ENTIRE SURFACE AREA 8 Reassemble the rear shackles and brackets with the new shackle pins E5HZ 5780 B for a 6 7 pin and E5HZ 5780 A for a 6 1 pin Prior to fully seating the shackle pins shift pry the spring away from the spot faced surface and install steel thrust washers F4HZ 5A879 A 0 030 and F4HZ 5A879 B 0 040 between the spring and shackle bracket Select the thrust washers to obtain the closest fit possible it may be necessary to spot face again if a slight adjustment is needed to obtain the tightest possible fit 9 Install all retaining nuts and bolts and torque to specifications using the appropriate Service Manual specifications 10 Remove the front spring pin perform Steps 6 15 on the front spring hanger bracket and spring 11 Lubricate all front suspension pivot points using the Ford approved lubricant XG 1 C 12 Remove the jack stands and lower the vehicle OTHER APPLICABLE ARTICLES NONE SUPERSEDES 92 12 22 94 18 14 WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 203200 303000 304000 702000 702100 Bulletin Contents TSB Article 95 12 12 has been superseded by Article 96 6 12 95 13 Publication Date JULY 3 1995 Art
19. 505000 597997 95 12 Publication Date JUNE 19 1995 Hood Check Cables Restrict Hood Opening Vehicles Without Bright Chrome Grille Article No Surround 95 12 10 MEDIUM HEAVY TRUCK 1989 95 LL 9000 LTL 9000 ISSUE The hood may not fully open on some vehicles This is due to insufficient length of the hood check cables ACTION Install new Hood Check Cables as outlined in the appropriate Service Manual Section 01 02 The cables were lengthened by 127mm 5 allowing more forward travel when the hood is tilted This allows the hood to travel beyond its center of gravity to fully open past its pivot point on vehicles with or without a bright chrome grille surround OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OASIS CODES 108000 95 12 Publication Date JUNE 19 1995 Suspension Front Popping Noise When Turning Article No Noise Popping Sound When Turning 95 12 11 MEDIUM HEAVY TRUCK 1988 94 L SERIES ISSUE TSB 92 12 22 provided new one piece spiral grooved bushings and TSB 93 18 17 provided bronze thrust washers to reduce front spring popping noises The bronze thrust washers were replaced with thicker hardened steel washers in TSB 94 18 14 Further analysis has revealed the need for additional tools for reaming the spring eyes and spot facing suspension connection points The procedures for using the new tools are incorp
20. Hold that position for 1 minute Figure 12 WHEEL END LUBRICATION PROCEDURE WITH AXLE ON LEVEL OIL WILL RUN OIL WILL RUN SURFACE FILL HOUSING INTO WHEEL END INTO WHEEL END WITH TO BOTTOM OF PLLIG NOTE TILT HOUSING SIDE TO SIDE 1 MINUTE PER SIDE TEMPERATURE SENSOR THEN RECHECK OIL LEVEL IN AXLE MOUNTING HOLE TB 4315 A Figure 12 Article 95 15 16 3 Lower the left side back to its original position 4 Raise the right side of the axle 6 152mm or more Hold that position for 1 minute Figure 12 5 Lower the right side back to its original position 6 With the axle level add lubricant through the axle housing cover filler hole until the fluid is level with the bottom of the filler hole NOTE AXLES WITHOUT WHEEL END FILL HOLES WILL REQUIRE APPROXIMATELY 2 5 ADDITIONAL PINTS OF LUBRICANT TO BRING THE LEVEL EVEN WITH THE BOTTOM OF THE FILLER HOLE OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS INFORMATION ONLY OASIS CODES 301000 302000 95 15 Publication Date JULY 31 1995 Article No Leaks Oil Front Cover Or Gear Housing Vehicles With FD1460 Engine 95 15 17 MEDIUM HEAVY TRUCK 1992 95 CARGO SERIES F SERIES L SERIES ISSUE There may be an oil leak from the front cover area on some vehicles with FD1460 engines Typical repair procedures for replacing gaskets may be ineffective A front engine cover design revision has occurred and was put into production in September 19
21. THE ORIGINAL DAMPER INCLUDED A PULLEY VIBRATION DAMPER AND ADAPTER AS A ONE PIECE ASSEMBLY THE REPLACEMENT PARTS ARE SEPARATE PULLEY DAMPER AND ADAPTER 9 Install the new crankshaft pulley FAHZ 6312 A Cummins 3926853 the new vibration damper F4HZ 6316 A Cummins 3914119 and the adapter FAHZ 6N304 A Cummins 3914121 using the new capscrews lubricated in Step 8 Using a Rotunda Engine Barring Tool 014 00264 or equivalent to stop engine rotation torque the damper capscrews to 200 N m 148 Ib ft 10 Install the fan drive belt as outlined in TSB 94 23 20 NOTE FOR VEHICLES WHICH CAME FACTORY EQUIPPED WITH A CRANKSHAFT DRIVEN POWER TAKE OFF PTO THE PTO ADAPTER FSHT 6K025 BA IS COMPATIBLE WITH AND MAY BE REINSTALLED ONTO THE NEW VIBRATION DAMPER ADAPTER F4HZ 6N304 A OTHER APPLICABLE ARTICLES 94 23 20 WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 497000 95 18 Publication Date SEPTEMBER 11 1995 Air Conditioning Discharge Line Fatique At A C Compressor R 12 Systems FD1460 Engines Article No Air Conditioning Lack Of Cooling R 12 Systems FD1460 Engines Discharge 95 18 11 Line Fatique At A C Compressor MEDIUM HEAVY TRUCK 1993 94 L SERIES ISSUE The air conditioning A C discharge line may fatique at the A C compressor on some vehicles This is due to vibration and the discharge line being unsupported near the A
22. USE C O HOSE ESHT 3A719 NA GAS USE C O HOSE HOSE FITTINGS USE C O FITTINGS EXCEPT AT THE GEAR INLET PORT ADD 45 DEGREE ELBOW 384285 87 TB 3491 B Figure 1 Article 95 15 15 Ross Gear Installation NOTE PLEASE REFER TO 1993 OR NEWER FORD SERVICE MANUAL SECTION 11 02 FOR DETAILS CONCERNING FINAL GEAR ADJUSTMENTS OF THE SECTOR SHAFT PITMAN ARM AND POPPET VALVES TO SUPPLEMENT THE GENERAL INSTALLATION OUTLINE GIVEN BELOW 1 Install the power steering pump per appropriate model year Service Manual NOTE THAT THIS NEW HIGHER PRESSURE PUMP IS REQUIRED BECAUSE THE ROSS TAS65 GEAR USES A HIGHER PRESSURE SYSTEM 150 BAR VS 140 BAR FOR BENDIX GEAR Place the gear on the side rail and install the nuts and bolts Torque bolts to 299 406 N m 220 300 Ib ft Install intermediate shaft U joint onto the steering gear input shaft Torque bolts to 68 95 N m 50 70 Ib ft Place new pitman arm on the steering gear sector shaft and align the arm s notch with the notch on the end of the sector shaft Use a chisel to spread the pitman arm and slide it onto the sector shaft WARNING DO NOT USE A HAMMER TO FORCE THE PITMAN ARM ONTO THE SECTOR SHAFT THIS COULD DAMAGE SECTOR SHAFT BEARINGS AND CAUSE LOSS OF GEAR PRELOAD 5 Install pitman arm pitch bolt and nut Torque nut to 299 406 N m 220 300 Ib ft 6 Attach pitman arm to drag link torque nut to 150 204 N m 111 151 Ib ft Insert cotter pin 7 Install 45 degree elbo
23. b Air solenoid valve may be faulty or plumbed incorrectly c Air line to clutch may be leaking Bendix Kysor air off fan drives d Fan temperature switch may be stuck open With engine temperature below 82 C 180 short across terminals If fan turns off switch is faulty e Pressure switch may be stuck open Turn off A C system If fan continues to run short across pressure switch if fan stops pressure switch is defective 7 Fan runs all the time when the air conditioning is off This is a normal condition in extremely hot weather Spray water on A C condenser fan should disengage for a short period of time and then rs engage after water evaporates b Air conditioning system may be overcharged or condenser covered with debris Tum OFF the system If the fan stops the refrigerant 8 Fan runs all the time when a the air conditioning is on C Pressure switch may have drifted out of calibration Use pressure gauge to compare actual fan on and fan off pressures to specified pressures Loose electrical connection b Fan temperature or pressure switch may be faulty 8 Fan operation is erratic FAN CLUTCH CONTROL SYSTEM DIAGNOSTIC PROCEDURE Sn pressure switch is functioning a Turn manual override off b Check air solenoid valve plumbing Replace valve if faulty c Check air lines Fix where
24. the warning switch may be inoperative or the switch to lamp wiring may have an open circuit 5 Remove the switch ground the metal collar on the switch and push in center pin If lamp illuminates switch is good If the warning lamp does not illuminate replace the switch If replacement of the switch does not cause the warning lamp to illuminate check the wiring If it still fails to illuminate replace the Differential Pressure Valve Assembly E6HZ 2K493 A Refer to Step 6 for installation then proceed to SECTION Ill NOTE IF THE VALVE IS NOT REPLACED IN STEP 5 RE CENTER THE VALVE BY USING THE PROCEDURE IN SECTION Ill STEP 3 6 Following are removal and installation procedures for Differential Pressure Valve Assembly Removal Refer to Figure 1 HYDRAULIC BOLT BRAKE LINE 56727 52 2 475 2 REQ D PRESSURE DIFFERENTIAL SWITCH PRESSURE DIFFERENTIAL VALVE ASSEMBLY Figure 1 Article 95 10 14 2B317 CLIP 1350382 5101 HYDRAULIC BRAKE LINE 28365 WASHER 44723 52 2 REQ D 33770 52 2 REQ D TIGHTEN TO 17 23 N m 12 17 LB FT TB 4214 A a Disconnect electrical connector at pressure differential switch b Clean dirt from around hydraulic line fittings Allow hydraulic fluid to drain into a suitable container c Remove clip which secures hydraulic line routed from T fitting at pressure differential valve assembly When positioning this or any hydraulic line aside take care not
25. AA Bracket Solenaid Air Bolt 5 16 1 1 01 sclenoid ta bracket Nut 5 16 18 solencid to bracket Bolt 1 4 20x0 99 bracket o hood stabilizer Nut 1 4 20 bracket to hood stabilizer 1 8 0 Tube FANSTAT 40 fan clutch 1 4 Q D Tube air manifold to sol air valve 174 Q D Tube sol air vave to FANSTAT 1 4 Tuba air manifold to sel air valve 30 1 8 Q D Tube sol ait valve to fan clutch 1 4 Q D Tuba D5TA 28418 AE0830 air valve to fan clutch X 897 p ora x X X W510 Mim ios X X x Strap 4 Bundling 95875 8 use as needed X Denotes that part is required for field fix installation Check vehicle and options that are applicable 8 O ring is used on the A C high pressure line at the high pressure switch port b If vehicle is older than model year 1989 replace existing solenoid air valve with this newer part c Bulk tubing DETA 2B417 AE cut to length and fitted at both ends with sleeve 383800 5 and nut 386478 5 forms 2B418 part d Not includad in kit must be ordered separately e Service part number TB 2574 C Figure 1 Article 95 25 14 INSTALLATION Installation of a new ON OFF fan clutch control system kit provides the following benefits The electrical temperature switch provides a more crisp fan clutch engagement A 3 minute time delay triggered
26. Auto Transmission Fluid XT 2 QDX E4AZ 19582 B or equivalent To check system for leaks remove air from the system and check power assist through range of wheel articulation Start engine rotate wheels from wheel stop to stop DO NOT HOLD THE WHEELS AGAINST THE STOPS FOR LONGER THAN 5 SECONDS If there is a significant increase in steering effort before reaching the stop bolts check them for proper setting If the bolt setting is correct or the setting has been corrected and stop bolts are not contacted refer to the Truck Service Manual Steering Diagnosis and Testing Section Refer to the Ford Service Labor Times Manual for applicable labor operations OTHER APPLICABLE ARTICLES NONE SUPERSEDES 94 25 8 WARRANTY STATUS INFORMATION ONLY OASIS CODES 303000 95 15 Publication Date JULY 31 1995 Brakes Rear Re index Rear Rear Brake Chamber To Eliminate Interference With DSO Article No Asphalt Spreader Option Tandem Axle Vehicles Used In Asphalt Spreader 95 15 16 Applications MEDIUM HEAVY TRUCK 1989 95 FT 800 FT 8000 FT 900 L SERIES ISSUE Standard rear axle brake chambers extend beyond the profile of the rear tires Dealer Special Order DSO offers the availability of an asphalt spreader option to re index the rear axle brake chambers away from the asphalt spreading device or other aftermarket apparatus Vehicles not ordered with this option and used in this vocation may experience an interference conce
27. Axle shaft Axle flange and tighten to specified torque 5 Lubricate axle wheel ends Refer to the Wheel End Lubrication Procedure in this article FOUR PIECE TANG DOWEL TYPE LOCKWASHER SYSTEM 1 Install the dowel type washer on the spindle NOTE IF THE DOWEL PIN AND WASHER ARE NOT ALIGNED REMOVE THE WASHER TURN IT OVER AND REINSTALL IF REQUIRED LOOSEN THE INNER NUT JUST ENOUGH FOR ALIGNMENT NEVER TIGHTEN THE INNER NUT FOR ALIGNMENT THIS CAN PRELOAD THE BEARING AND CAUSE PREMATURE FAILURE Install the tang type lockwasher on the spindle Install the outer nut on the spindle and tighten to 339 N m 250 Ib ft Verify end play Refer to the End Play Verification Procedure in this article After verifying end play secure the outer nut by bending two 2 opposing 180 degrees apart tangs of the locking washer over the outer nut as shown in Figure 9 Install a New gasket at axle shaft flange b Axle shaft Axle flange and tighten to specified torque Lubricate axle wheel ends Refer to the Wheel End Lubrication Procedure in this article END PLAY VERIFICATION PROCEDURE 1 Verify that end play meets specification using dial indicator An indicator with 0 001 0 025mm resolution is required Wheel end play is free movement of the tire and wheel assembly along the spindle axis Attach a dial indicator with its magnetic base to the hub or brake drum as shown in Figure 10 WITH INDICATOR MOUNTED A
28. Disconnect the drag link from the pitman arm 4 Remove the pitman arm pitch bolt and nut save for reuse Optional Remove the pitman arm from the sector shaft using Pitman Arm Puller T64P 3590 F 5 Remove intermediate shaft U joint nut and bolt and disconnect it from the steering gear input shaft 6 Disconnect steering gear mounting hardware and remove the gear from the truck s side rail 7 Remove power steering pump per Service Manual Section 13 pre 1993 model years instructions NOTE REFER TO FIGURE 1 FOR PART USAGE INFORMATION STEERING GEAR CONVERSION CHART F SERIES MODEL YEARS 1989 THROUGH 1993 10 12000 LB FRONT AXLES BENDIX 500 TO ROSS TAS65 GEAR F2HT 3N503 CA C500N E7HZ 3504 H TAS65 F1HT 3N503 JA C500N FOHT 3N503 C C500N HARDWARE USE C O BOLTS USE NUTS AND WASHERS PITMAN ARM F2HT 3590 DA F3HZ 3590 C E8HT 3580 AA USE FOR BOTH DA AND AA ARMS PINCH BOLT NUT lee 1 0 m USE C O BOLT AND NUT DRAGLINK E8HT 3364 AA USE C O DRAGLINK ATTACHING HARDWARE USE C O HARDWARE POWER STEERING PUMP E8HT 3A674 AA E8HZ 3A874 M FOR 1988 THROUGH NOVEMBER 1990 674 FNH DIESEL F3HZ 3A874 F FOR NOVEMBER 1990 THROUGH 1993 ESHT 3A674 CA CUMMINS FAHZ 3A674 D AIR BRAKES F3HT 34674 AB CUMMINS FAHZ 3A874 F HYDRAULIC BRAKES POWER STEERING E8HT 3K514 BA GAS F4HZ 3A674 C PUMP AND RESERVOIR POWER STEERING HOSES E8HT 3A719 CA DIESEL
29. Loctite 5900 or Cummins Three Bond Sealer 3823494 NOTE THE FRONT COVER MUST BE INSTALLED AND BOLTS TORQUED WITHIN 15 MINUTES FROM WHEN LOCTITE 5900 OR CUMMINS 3823494 WAS APPLIED IF THE LIQUID GASKET APPEARS SKINNED OVER IT WILL NOT CREATE A GOOD SEAL IT MUST BE CLEANED FROM THE FRONT COVER AND NEW LIQUID GASKET APPLIED AND INSTALLED IN 15 MINUTES 14 Install the front cover and torque all of the bolts Ensure the long and short bolts are in the proper location Refer to Figure 4 for bolt locations Torque the long bolts 3926863 CF with the 11mm head to 35 N m 26 Ib ft Torque the short bolts 3925883 CF1 with the 10mm head to 24 N m 18 Ib ft SUNRISE FRONT COVER LOCATION OF SIX 6 LONG BOLTS 3926863 CF TB 4191 A Figure 4 Article 95 15 17 NOTE BE SURE TO USE A TORQUE WRENCH WHEN TIGHTENING THE HIGH STRENGTH BOLTS OVER TIGHTENING MAY LEAD TO STRETCHING THE BOLTS THE COATING ON THE BOLTS REDUCES FRICTION DURING TIGHTENING SO TIGHTENING BY FEEL MAY RESULT IN OVER TIGHTENING A TORQUE WRENCH MUST BE USED TO ENSURE PROPER RETENTION LEVEL IS ACHIEVED ON ALL ATTACHING FASTENERS 15 Reinstall all components removed through this process according to the appropriate Service Manual procedures The high strength coated bolts 3926846 CF and 3926863 CF may be reused with the following guidelines Check the bolt for any sign of stretching or damage to the threads If the bolt is damaged do not reuse
30. REFERENCE 93 7 a 44879 82 WASHER 2 REQUIRED i FAHT 6038 AA a INSULATOR ASSEMBLY FRONT OF VEHICLE 2 6 095 SPACER FRONT MOUNT 2 REQUIRED WASHER 58687 S2 2 REQUIRED BOLT 2 REQUIRED TB 3247 B Figure 3 Article 95 23 15 4 nstall the new bolts nuts and washers as described in the appropriate sketch Refer to Figures 1 2 and 3 Tighten nuts to 102 142 N m 75 105 Ib ft 5 Blockthe transmission to prevent movement damage when the mounts are removed 6 Remove and RETAIN the two 2 bolts and the rear engine support cap retaining the rubber isolator to the frame bracket Also remove and RETAIN the four 4 bolts retaining the mount to the transmission 7 Remove the rubber isolators from the bracket and discard 8 Install the new rubber isolators with the voids at the top and bottom of the bracket Refer to Figure 4 ALL HEAVY TRUCK MODELS WITH FD1060 1460 DIESEL ENGINE KITS A B AND C TRANSMISSION VIEW D REAR MOUNT NOTE INSULATOR MUST REFERENCE BE INSTALLED WITH VOIDS VERTICAL AS SHOWN F4HZ 6068 A INSULATOR ASSEMBLY REAR 2 REQUIRED VIEW IN DIRECTION OF ARROW X SHOWING INSULATION Hen 52 a REQUIRED Lm e TIT REAR SPRING gt BRACKET uL REFERENCE E E 44879 32 WASHER 4 REQUIRED 3 32 789 34989 52 gt NUT 4 REQUIRED
31. The jumper wire assembly has a built in resistor to reduce the possibility of false illumination of the Stop Engine lamp SERVICE PROCEDURE CONCERNS CONCERN 1 The latest generation Detroit Diesel Electronic Engine Control DDEC III requires the low coolant sensor circuit to have a 560K Ohm resistor for the diagnostic system to function properly For 1994 1 2 through 1995 L Series vehicles this resistor is not present This could cause a connector not engaged fault code To resolve this concern a Service Jumper Wire Assembly F5HZ 12A690 L has been released which contains the resistor The assembly consists of both mating connectors and can be installed between the low coolant sensor and the engine wiring harness All vehicles should have this wiring assembly installed if it is not already present CONCERN 2 The Engine Wiring Harness 14365 has two 2 identical electrical connectors at the same location These connectors will both engage the low coolant level sensor connector A visual check should be made if a connector not engaged code is present to ensure the color coding from the engine wiring assembly is GY Y and O BL If the connector containing the PK and BK wires is connected to the low coolant sensor remove it and install the connector which contains the GY Y and O BL wires CONCERN 3 The polarity of the low coolant level sensor has been found to be incorrect This will cause an advanced corrosion build up condition
32. To 9 1 94 Article No Heater Air Conditioning Little Or No Air From Defrost Register Vehicles Built 95 5 29 From 12 1 91 To 9 1 94 MEDIUM HEAVY TRUCK 1991 95 L SERIES ISSUE Air may not blow out of the defrost registers when control lever is in defrost mode on some vehicles This is due to a malfunctioning control valve assembly ACTION Verify vehicle has a malfunctioning valve assembly by positioning the selector lever in the defrost mode If the selector does not firmly stay in the defrost position or little air blows through the defrost register while the fan is operating install the new valve assembly F4HZ 18B679 A or F4HZ 18B679 B identified by raised letters F 94 according to the following service details REMOVAL 1 Remove access panel which surrounds the control and remove the two 2 fasteners which secure the control to the instrument panel Carefully pull control assembly back to expose the temperature door cable anchor point With needle nosed pliers or blade type screwdriver pinch the blue fitting snap in tangs and push the fitting out of the square hole Hold control firmly with one 1 hand to preclude any type of bending of the plastic bracket when applying force of any kind With the blue fitting free it will now be possible to disengage the Z bend at the end of the wire from the control temperature lever hole Some articulation of the cable end is required Disconnect the tube harness by pressi
33. adequately indicate the coolant temperature ACTION Install a new temperature sender fitting This will allow the sensor to be positioned in the main engine coolant flow and will provide a more representative temperature reading Refer to the following Service Procedure for details SERVICE PROCEDURE REMOVAL Refer to Figure 1 ORIGINAL INSTALLATION Item Description FRONT OF 1 Hose VEHICLE 2 Hose Clamp es ENGINE CYLINDER HEAD o m2 6 Water Temperature Sender T Bushing 8 Tube Assembly TB 4365 A Figure 1 Article 95 20 12 Partially drain the cooling system Refer to the appropriate year F B or L Series Powertrain Drivetrain Service Manual Section 03 03 for cooling system draining filling and bleeding Electrically disconnect the water temperature sender Loosen the hose clamp and remove the hose from the connector Remove the connector from the bushing and retain Remove the bushing from the tee and retain Remove the water temperature sender from the bushing and retain Remove the bushing from the tee and discard Remove the tee from the tube assembly and discard NOTE DURING REASSEMBLY ALL THE THREADED FITTINGS SHOULD BE WRAPPED WITH A THREAD SEALING TAPE OR COATED WITH A THREAD SEALER TO PREVENT COOLANT LEAKS INSTALLATION Refer to Figure 2 REVISED INSTALLATION Eike Tube Assembly im i CYLINDER HEAD Item 2 3 4
34. correct installation torque OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 402000 95 18 Publication Date SEPTEMBER 11 1995 Cooling Fan Cracks On Fan Pulley Support Bracket Vehicles Built Through 6 1 95 Article No With Cummins N14 Engine 95 18 14 MEDIUM HEAVY TRUCK 1988 95 L SERIES ISSUE The fan pulley support bracket may crack along its base where it attaches to the engine This may be due to stress after improper installation procedures ACTION If the fan pulley support bracket requires servicing due to cracking or if service to the engine is required that demands the bracket be removed refer to the following Service Procedure for proper installation procedures SERVICE PROCEDURE REMOVAL AND INSPECTION 1 Refer to Section 03C 05 of the 1995 L Series Powertrain Drivetrain Service Manual to remove the fan belts fan fan clutch and supporting brackets 2 Remove the bracket and inspect for cracks The cracks will generally appear along the lower base of the bracket where it mounts to the engine If cracks are found the bracket must be replaced If the bracket is free of cracks and otherwise serviceable then reinstall it by referring to the Installation procedure that follows INSTALLATION 1 Install bracket Figure 1 Item 1 onto the engine using two 2 bolts and washers Figure 1 Items 2 and 3 Torque th
35. indexed by measuring from the exhaust manifold to the cast boss in the compressor housing Figure 1 View A The measurement should be 4 88 0 12 124mm 3mm NOTE CLAMPS MUST BE INSTALLED AS CLOSE TO PIPE BEADS AS POSSIBLE Cum beer MET a vo e ru ca 5 Spring Loaded Clamp Figure 1 Article 95 17 12 THE TOOL PARTING LINE ON THE OUTBOARD SIDE ALIGN LOCATION MARK ON THE ADAPTER WITH L OF THE COMPRESSOR HOUSING 4 88 124mm EXHAUST MANIFOLD ADJUST TURBO AT ASSEMBLY LOOSEN TURBO CLAMP RE INDEX TURBO TO ACHIEVE 4 88 0 12 124 3mm CLEAR TO EXHAUST MANIFOLD RE TORQUE y COMPRESSOR PARTING LINE CLAMP TO 15 19 LB FT 20 26 N m T8 4166 A 3 If measurement is not within specification loosen the clamp between the turbocharger center housing and the turbocharger compressor housing Remove the hot side tubing clamp Figure 1 Item 3 from the compressor housing and remove the adapter Figure 1 Item 1 4 Rotate the compressor housing until the boss on the housing is 4 88 0 12 124mm 3mm from the exhaust manifold Figure 1 View A Torque the clamp to 15 19 Ib ft 20 26 N m Check the condition of the adapter O ring Figure 1 Item 2 replace if necessary F1HZ 6C653 A Reinstall the adapter aligning the locator marks as shown in Figure 1 Torque the clamp to 85 115 Ib in 9 6 13 N m OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Elig
36. location 2 Remove the cab floor transmission access panel including the shift boot Remove panel and boot over the shift lever 3 Remove the shift tower lever assembly from the top of the transmission Discard the gasket and retain the bolts for reuse 4 Install the new shift lever assembly refer to chart in this article for correct part application and gasket 3208 N 1080 Torque bolts from 34 47 N m 25 35 Ib ft 5 Install the floor transmission access panel removed in Step 2 6 Install the shift knob removed in Step 1 and reinstall the air lines to the shift knob OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 505000 505200 702000 703000 95 14 Publication Date JULY 17 1995 Article No Clutch New Clutch Rod Assemblies With Improved Swivel Bushings 95 14 15 MEDIUM HEAVY TRUCK 1993 95 F SERIES L SERIES ISSUE Clutch rod assemblies with improved bushing to housing containment have been released for service The improved clutch rod should reduce the possibility of the bushing becoming attached to the ball portion of the swivel thus spinning the bushing in the housing ACTION If service to the clutch rod assembly becomes necessary replace the clutch rod assembly with an improved clutch rod assembly Refer to the following Application Chart for the proper Service Part numbers Refer to Section 08 02 of t
37. the paint surface Follow the manufacturer s recommended procedures NOTE FORD DOES NOT RECOMMEND THE USE OF OXALIC ACIDS OR OTHER FALLOUT REMOVERS 1 2 Rinse off dust and debris with cold water Be sure to start at the bottom and work up Prepare product 1119 by mixing one 1 part 1119 with four 4 parts cold water Use clean wash mitt and apply mixture to entire car starting at the bottom and working up to the top surface Keep car wet with the solution for 5 to 10 minutes Do not allow product to dry on the car and do not allow it to streak down the sides Rewipe with mitt if necessary to avoid streaks Rinse car with cold water Dry the flat surfaces of the vehicle hood roof and deck lid Apply product 883 directly to the contaminated surfaces using a clean dry sponge wash mitt or soft truck brush 883 is ready to use from the bottle with no mixing involved Keep the areas wet with the 883 for 5 to 7 minutes Do not allow to dry on the car Wipe down to the body line on the sides Prepare product 118SC by mixing 1 oz 0 03 L with 1 gal 3 785 L of water Shampoo the vehicle with 118SC shampoo mixture using a clean wash mitt and then rinse with cold water NOTE DO NOT USE 118SC MITT WITH 1119 OR 883 SOLUTIONS USE SEPARATE MITTS AND ALWAYS KEEP THEM SEPARATE Inspect paint surface to see if rust particles have been removed If rust particles have been on the vehicle for a long time it may be nec
38. to bend or crimp d Remove nut and washer from retaining attaching bolt Withdraw both bolts and remove pressure differential assembly Installation Refer to Figure 1 a Position pressure differential assembly on frame side rail and install forward bolt b Install remaining attaching bolt securing hydraulic line and clip at pressure differential assembly C Install line fittings to pressure differential assembly d Tighten pressure differential assembly attaching bolts to 17 23 N m 12 17 lb ft e Tighten hydraulic line fittings to 17 23 N m 12 17 Ib ft f Connect electrical connector at pressure differential switch 7 g Fill reservoirs with Ford Heavy Duty Brake Fluid C6AZ 19542 AA or BA ESA M6C25 A or an equivalent DOT 3 fluid to fill mark and bleed system If the brake warning lamp remains on after Step 1 there may be a shorted or broken switch grounded switch wires or an non centered pressure differential valve Remove the switch from the valve If the lamp remains on check the wiring for a ground If the lamp goes out check the switch and replace if necessary Reinstall the switch in the valve bogy If the lamp comes on again the valve is not centered Re center the valve by disconnecting the red supply line and very slowly applying the brake If the lamp goes out reconnect the supply line and go to SECTION Ill Step 3 If the lamp stays on reconnect the red supply line and disconnect the green line Aga
39. x 1 44 x 13 GRADE 8 FLATWASHER PITMAN ARM ESHT 3590 EB 6 7000 LB F A F4HZ 3590 A TAS40 ESHT 3590 BB 8 9000 LB F A F3HZ 3590 B TASS5 DRAGLINK E8HT 3304 AA USE DRAGLINK ATTACHING HARDWARE USE HARDWARE POWER STEERING PUMP ESHT 34674 AA ESHZ 3A674 M FOR 1988 THROUGH NOVEMBER 1990 F1HT 3A674 FA FNH DIESEL F3H2 3A674 F FOR NOVEMBER 1990 THROUGH 1993 ESHT 3A674 CA CUMMINS DIESEL F4HZ 3A874 D AIR BRAKES F3HT 3A674 AB CUMMINS DIESEL F4HZ 3A674 F HYDRAULIC BRAKES POWER STEERING E8HT 3K514 AA GAS F4HZ 3A674 B PUMP AND RESERVOIR POWER STEERING HOSES 3 719 DIESEL USE C O HOSE ESHT 34719 NA GAS USE C O HOSE HOSE FITTINGS USE FITTINGS EXCEPT THE GEAR INLET PORT ADD 45 DEGREE ELBOW 384285 57 TB 3492 B Figure 2 Article 95 15 15 Ross Gear Installation NOTE PLEASE REFER TO 1993 OR NEWER FORD SERVICE MANUAL SECTION 11 02A FOR DETAILS CONCERNING FINAL GEAR ADJUSTMENTS OF THE SECTOR SHAFT PITMAN ARM AND POPPET VALVES TO SUPPLEMENT THE GENERAL INSTALLATION OUTLINE GIVEN BELOW 1 Place the gear on the side rail and install the nuts and bolts Torque bolts to 407 433 N m 300 320 Ib ft NOTE INSTALL THE 3 4 BOLTS WITH THE BOLT HEADS OUTBOARD AND NUTS INBOARD 2 Install intermediate shaft U joint onto the steering gear input shaft Torque bolts to 68 95 N m 50 70 Ib ft 3 Place the pitman arm on the steering gear sector shaft and align the a
40. 0 1 5 25 9 8 hex head bolt N605545 S100 Item 4 Figure 1 to secure the tubular bracket over the air cleaner support bracket to the charged air cooling casting Torque bolt from 41 62 N m 30 46 Ib ft b LN Series Install a M10x1 5x20mm 9 8 hex head bolt 605544 52 Item 4 Figure 2 through the tubular support bracket directly to the charged air tubing casting Torque bolt from 41 62 N m 30 46 Ib ft 5 Fill and bleed the Hydromax system to the proper level using Motorcraft Mercon or equivalent Refer to the appropriate Service Manual Section 06 05B for proper fill and bleeding procedure OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 301000 95 10 Publication Date MAY 22 1995 Article No 95 10 14 Brakes Air Over Hydraulic Supplemental Diagnostic Procedures MEDIUM HEAVY TRUCK 1986 89 CARGO SERIES ISSUE Diagnostic and repair service information concerns for air over hydraulic brake systems may occur for some vehicles The following diagnostic procedures are intended to supplement the information published in the 1986 89 Cargo Truck Service Manual ACTION Please refer to the following Sections for service details CONTENTS SECTION I INSPECTION PROCEDURE SECTION II PRESSURE DIFFERENTIAL VALVE ASSEMBLY DIAGNOSTIC AND REPLACEMENT SECTION Ill DIFFERENTIAL VALVE FUNCTIONAL CHECK SECTIO
41. 1 Article 95 4 11 5 Clean and reinstall the sensor into the reservoir Ensure Service Jumper F5HZ 12A690 L has also been installed between the engine wiring harness and the low coolant level sensor Refill coolant as necessary OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 203000 203200 206000 698298 95 5 Publication Date MARCH 13 1995 Article No Air Conditioning Adding Refrigerant Oil Service Tip 95 5 12 FORD 1990 93 FESTIVA 1990 94 TEMPO 1990 95 CROWN VICTORIA ESCORT MUSTANG PROBE TAURUS THUNDERBIRD 1994 95 ASPIRE LINCOLN MERCURY 1990 92 MARK VII 1990 94 TOPAZ 1990 95 CONTINENTAL COUGAR GRAND MARQUIS SABLE TOWN CAR TRACER 1991 94 CAPRI 1993 95 MARK VIII MERKUR 1990 SCORPIO LIGHT TRUCK 1990 BRONCO II 1990 95 AEROSTAR BRONCO ECONOLINE F SUPER DUTY F 150 350 SERIES RANGER 1991 95 EXPLORER 1993 95 VILLAGER 1995 WINDSTAR MEDIUM HEAVY TRUCK 1990 91 C SERIES CL CLT 9000 SERIES 1990 95 CARGO SERIES F amp B SERIES L SERIES ISSUE Current repair procedures do not advise on the addition of refrigerant oil to the A C system when a minor repair is made ACTION Add 0 06 L 2 oz of the proper type new refrigerant oil to the system before recharging when servicing concerns that do not require major component replacement Repairs considered minor are O ring leaks charge p
42. 1 using four 4 new U bolts 2 of F2HZ 5705 D and 2 of F2HZ 5705 C eight 8 new 384033 S2 7 8 14 torque prevailing nuts and the spherical and flatwashers removed earlier if serviceable Torque U bolts to 542 610 N m 400 450 Ib ft as outlined in the L Series Service Manual Section 04 02E AXLE SEAT 4362 Figure 1 Article 95 25 16 10 Recheck the ride heights and set to specifications if needed OTHER APPLICABLE ARTICLES 92 13 18 92 19 10 94 20 26 WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 703000
43. 2 Usa original power and ground connection points 4 Remove the 1 4 air line and fittings between the air solenoid valve 8C180 and the fan stat BK612 5 Remove the 1 8 air line and fittings between the fan stat 8K612 and the fan clutch 27 Also remove the 1 8 air inlet adapter from the fan clutch Replace it with the 1 4 air inlet adapter 383833 5102 included in the repair kit 6 Replace the removed air lines with the 1 4 air line 2B418 included in the kit See Figure 3 Line routes from fan clutch to air solenoid valva NOTE For pre 1989 vahicles with check the part number on the air solenoid valve 8 180 If it does not have an ESHT prefix replace the valve with one that does ON OFF FAN CONTROL SYSTEM REPLACEMENT KIT F2HZ 8C609 A FOR L 9000 SERIES WITH BENDIX CLUTCH AND AIR CONDITIONING INSTALLATION INSTRUCTIONS CPR 1993 FORD MOTOR COMPANY DEARBORN MICHIGAN 48121 9 93 TB 3315 B Figure 5 Article 95 25 14 FORD HEAVY TRUCK FAN CLUTCH OPERATION WITH INDEX CONTROL SYSTEM FIELD FIX WITH AIR CONDITIONING AIR FLOWS FROM THE AIR SUPPLY TO THE AIR SOLENOID VALVE WITH THE A C REFRIGERANT PRESSURE AND THE ENGINE COOLANT TEMPERATURE WITHIN NORMAL RANGES ELECTRIC CURRENT FLOWS THROUGH THE COOLANT TEMPERATURE SWITCH AND THE A C REFRIGERANT HIGH PRESSURE SWITCH TO THE AIR SOLENOID VALVE THE CURRENT OPENS THE NORMALLY CLOSED AIR SOLENOID VALVE SO T
44. 3 OTHER APPLICABLE ARTICLES 91 18 1 92 6 4 WARRANTY STATUS Eligible Under The Provisions Of 12 Month 12 000 Mile Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 106000 Bulletin Contents TSB Article 95 6 20 has been superseded by Article 95 9 12 Bulletin Contents TSB Article 95 6 21 has been superseded by Article 95 11 17 Bulletin Contents TSB Article 95 7 2 has been superseded by Article 95 23 1 95 7 Publication Date APRIL 10 1995 Fuel Injection Pump Bosch Service Information For Ford New Holland FNH 6 6L Article No 7 8L And Ford FD1060 1460 Midrange Diesel Engines 95 7 22 MEDIUM HEAVY TRUCK 1986 95 CARGO SERIES F amp B SERIES L SERIES ISSUE There have been several requests from the field about the Bosch policies and procedures regarding Unit Down Vehicle Off Road VOR diesel fuel injection pump repairs on Ford vehicles This TSB provides detailed information from Bosch regarding its policies and procedures on VOR repairs ACTION Refer to the following text for Bosch policies and procedures for VOR repairs The Bosch VOR system is an important element in providing prompt customer service The system is used in the event specific service parts are not locally available to perform a repair for a unit down situation The VOR system is provided only upon request If it is not requested then either the Bosch regular order 3 to 5 days or r
45. 5HZ 17526 B Two 2 are required per vehicle NOTE REPLACEMENT BLADE ASSEMBLIES FOR THIS ARM ARE THE 1995 L SERIES BLADE F5HZ 17528 A OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS INFORMATION ONLY OASIS CODES 202000 95 6 Publication Date MARCH 27 1995 Paint Iron Particle Removal Industrial Fallout Acid Rain Neutralization Paint Rough Texture Ferrous Metal Contamination Acid Rain Discoloration Or Etching FORD 1980 and after CROWN VICTORIA ESCORT MUSTANG THUNDERBIRD 1982 88 EXP 1984 94 TEMPO 1986 and after TAURUS 1988 93 FESTIVA 1989 and after PROBE 1994 95 ASPIRE 1995 CONTOUR LINCOLN MERCURY 1980 and after CONTINENTAL COUGAR GRAND MARQUIS TOWN CAR 1981 87 LYNX 1984 92 MARK VII 1984 94 TOPAZ 1986 and after SABLE 1987 89 TRACER 1991 94 CAPRI 1991 and after TRACER 1993 and after MARK VIII 1995 MYSTIQUE MERKUR 1985 89 XR4TI 1988 89 SCORPIO LIGHT TRUCK 1980 and after F 150 350 SERIES 1981 and after ECONOLINE 1982 and after BRONCO 1983 and after RANGER 1984 90 BRONCO II 1986 and after AEROSTAR 1988 and after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 and after WINDSTAR MEDIUM HEAVY TRUCK 1980 91 C SERIES CL CLT 9000 SERIES 1980 and after F amp B SERIES L SERIES 1986 and after CARGO SERIES ISSUE Article No 95 6 1 Ferrous metal particles hot iron dust are generated by manufacturing facilities rail shipments combust
46. 6 13 15 95 18 Publication Date SEPTEMBER 11 1995 Cooling System Overheats And Or Drive Belts Come Off Vehicles With Horton Fan Article No Clutch 95 18 13 MEDIUM HEAVY TRUCK 1993 95 L SERIES ISSUE The engine may overheat and or the drive belts may come off due to failure of the Horton fan clutch ACTION Replace the fan clutch with a revised fan clutch The new fan clutch has a redesigned bearing to reduce the possibility of fan clutch failure Refer to the following Service Procedure for details SERVICE PROCEDURE 1 Remove the bolts and washer which retain the fan blade to the fan clutch Remove the fan blade and spacer if equipped Retain the fan blade spacer and fasteners for reuse 2 Remove the air line which connects to the clutch 3 Loosen the clutch adjustment to relieve tension on the belt 4 Remove the bolts and washers which retain the clutch to the engine Remove the clutch and discard Retain the fasteners for reuse 5 Refer to the following Application Chart and install the proper clutch Refer to the Standard Torque Specifications located in the beginning of the L Series Service Manual for the correct installation torque Set the belt tension listed in the appropriate L Series Service Manual Section 03C 05 6 Reinstall the air line fan blade and spacer if equipped removed above Refer to the Standard Torque Specifications located in the beginning of the L Series Service Manual for the
47. 90 Newtons N 90 110 Pounds Force Ib on the belts Tighten the jam nuts on the adjusting link Torque the generator mounting nut to 102 142 N m 75 105 Ib ft 6 Start the engine and allow it to run for 10 minutes Stop the engine and recheck the drive belt tension If the belt tension has dropped below 934 Newtons N 210 Pounds Force Ib readjust the fan clutch to obtain 1112 1156 Newtons N 250 260 Pounds Force Ib OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 206000 303000 402000 497000 95 10 Publication Date MAY 22 1995 Brakes Hydraulic Hydromax Brake Reservoir Mounting Bracket Separation Article No Vehicles Equipped With Hydraulic Brakes And FD1060 Engine 95 10 13 MEDIUM HEAVY TRUCK 1995 F amp B SERIES L SERIES ISSUE A Hydromax brake reservoir mounting bracket separation concern may occur on some vehicles The separation occurs where the reservoir mounting brackets are welded to the reservoir Seepage of automatic transmission fluid may appear at the separated area resulting in low fluid level in the brake power assist system A low fluid level would activate the electric brake assist motor which actuates the BRK ELEC MTR brake electric motor warning lamp and a buzzer would sound These symptoms are caused by varying vibration between subject models resulting in early reservoir bracket separatio
48. 94 A list of service changes to resolve this condition are as follows New service steel edged moulded rubber gasket e New formed in place front cover gasket New sunrise gear cover Improved capscrews with a property class of 10 9 Improved air compressor mounting ACTION If service is required replace the front cover and gasket with the improved design If required also replace the gear housing Refer to the following Service Procedure for details NOTE FOR THIS REPAIR TO BE COMPLETELY EFFECTIVE ALL THE NEW COMPONENTS LISTED ABOVE MUST BE USED SERVICE PROCEDURE 1 Remove the cooling module Refer to the appropriate Service Manual Section 03 03 for details On certain vehicles it may be necessary to remove the hood to gain access Refer to the appropriate Service Manual Section 01 02 for details 2 Remove the front cover and gear housing including the camshaft air compressor fuel injection pump vibration damper and main drive pulley valve covers valve tappets push rods and rocker lever assemblies Refer to the appropriate Service Manual Section 03B 01 3 Inspect the gear housing for damage such as cracking around the mounting holes If condition of the housing is good clean all gasket material from the front cover and reuse the housing Use a wire wheel on a drill motor at low speed to clean the RTV out of the gear cover grooves If the gear housing is cracked or damaged replace the housing with a n
49. AIR VALVE TO FAN CLUTCH 83 DETAIL OF AIR SOLENOID VAEVE MOUNTING 1 4 0 0 TUBE 5612182 ESHT SCTSO AA AIR MANIFOLD F TO SOLENOID AIR VALVE 307 gt 54 383833 5102 379930 52 56704 52 FIGURE 3 VIEW IN DIRECTION OF ARROW Z LS 6328A SHEET 3 OF 3 CPH O 1993 FORD MOTOR COMPANY ON OFF FAN CONTROL SYSTEM REPLACEMENT DEARBORN MICHIGAN 48121 KIT 2 2 8 609 FOR L 9000 SERIES WITH 933 BENDIX CLUTCH W O AIR CONDITIONING INSTALLATION INSTRUCTIONS TB 3320 B Figure 10 Article 95 25 14 DESCRIPTION The new system uses a coolant temperature sensing switch to trigger an air solenoid valve providing crisper fan engagements than the current wax pellet fan stat Refer to the Parts List And Application Chart Figure 1 for a list of components in each kit and proper parts usage for each truck series Note that an appropriate wire harness must be ordered separately from the control system kit ON OFF FAN CLUTCH CONTROL SYSTEM PARTS LIST AND APPLICATION CHART L 9000 SERIES WITH BENDIX FAN mar T ENGINEERING Te PART NUMBER PART DESCRIPTION ATA Valve Ass y Fan Thermostat Control FANSTAT INDEX Temp Timer F3HT 108843 SA Electrical Temperatura F3HZ 10584 C aj Swilch Wig ety A a FWIWDN SA Wing A umge 0 190887 Wiring Ass y A C Jumper e F3HT 19D887 DA Wiring Ass y Jumper d Connector Wire Ass y F3HT 14806
50. ARE CORRODED a Inspect the tang type washer if used Replace the washer if the tangs are broken cracked or damaged Install the hub and drum on the spindle with care to prevent damage or distortion to the wheel seal CAUTION A WHEEL DOLLY IS RECOMMENDED DURING INSTALLATION TO ENSURE WHEEL SEAL IS NOT DAMAGED BY THE WEIGHT OF THE HUB AND DRUM NEVER SUPPORT THE HUB ON THE SPINDLE WITH JUST THE INNER BEARING AND SEAL THIS CAN CAUSE DAMAGE TO THE SEAL AND CAUSE PREMATURE FAILURE a Completely fill the hub cavity between the inner and outer bearing races with the same lubricant used in the axle sump Before installation lubricate the outer bearing with the same lubricant used in the axle sump NOTE LUBRICATE ONLY WITH CLEAN AXLE LUBRICANT OF THE SAME TYPE USED IN THE AXLE SUMP DO NOT PACK BEARINGS WITH GREASE BEFORE INSTALLATION GREASE WILL PREVENT THE PROPER CIRCULATION OF THE AXLE LUBRICANT AND MAY CAUSE WHEEL SEAL FAILURE Install a The outer bearing on the spindle b inner nut on the spindle c Tighten the inner nut to 271 N m 200 Ib ft while rotating the wheel hub CAUTION NEVER USE AN IMPACT WRENCH TO ADJUST WHEEL BEARINGS A TORQUE WRENCH IS REQUIRED TO ASSURE THE NUTS ARE PROPERLY TIGHTENED Back off the inner nut one 1 full turn Rotate the wheel hub Retighten the inner nut to 68 N m 50 Ib ft while rotating the wheel hub Back off the inner nut exactly 1 4 turn NOTE THIS ADJUSTMENT PROCEDURE A
51. ARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 610000 611000 614000 95 4 Publication Date FEBRUARY 27 1995 Reduced Engine Power Incorrect Illumination Of The Stop Engine Lamp Vehicles With Detroit Diesel Series 60 Engines DDEC III Built After 11 30 94 Warning Lamp Illumination Stop Engine Incorrect Illumination On Vehicles With Article No Detroit Diesel Series 60 Engines DDEC III Built After 11 30 94 95 4 11 Warning Lamp Stop Engine Incorrect Illumination Vehicles With Detroit Diesel Series 60 Engines DDEC III Built After 11 30 94 MEDIUM HEAVY TRUCK 1994 95 L SERIES ISSUE On some vehicles the Stop Engine Engine Warning or Engine Fluids lamp may illuminate incorrectly This may be caused by a missing resistor in the low coolant level sensor circuit wrong connector being installed on the coolant sensor or corrosion built up on the sensor Depending on the programming of the electronic control assembly the affects could range from illumination of the Stop Engine light to decreased engine power or the engine being shut off ACTION Determine the cause of the concern by using the following Service Procedure If necessary install a Jumper Wire Assembly F5HZ 12A690 L into the low coolant level sensor wiring harness by unplugging the low coolant level sensor and installing the jumper between the sensor and sensor connector
52. Bulletin Contents TSB Article 95 2 13 has been superseded by Article 95 4 10 95 2 Publication Date JANUARY 30 1995 Article No Heater Hot Air Entering The Passenger Compartment At All Times 95 2 14 MEDIUM HEAVY TRUCK 1992 95 CARGO SERIES ISSUE Full heat may be entering the passenger compartment from the heater assembly When this condition exists moving the heater temperature control lever to the COLD position will have no effect on decreasing the amount of heat entering the passenger compartment This may be caused by the heater core inlet supply hose being installed on the outlet side of the heater core The Cargo heater design uses the control valve on the outlet side of the core If the heater is plumbed in reverse engine coolant flow to control valve the control valve will not keep coolant flow from entering circulating through the heater core resulting in continuous hot air output ACTION Remove the heater core supply hoses and reverse their positions Refer to the following for details SERVICE PROCEDURE 1 Drain enough coolant from the cooling system to ensure the heater core is empty 2 Remove the hose clamps on the heater hoses at the heater core 3 Remove the hoses from the heater core and switch their positions 4 Reinstall the hose clamps and torque to 30 40 Ib in 3 4 4 5 N m 5 Replace the engine coolant following the instructions in the Owner Guide OTHER APPLICABLE ARTICLES NONE WARRANTY S
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54. C compressor ACTION Install new A C discharge line The new assembly has a support bracket brazed onto it This support bracket will be secured to the existing A C compressor mounting bolt Refer to the following procedure for service details NOTE VEHICLES EQUIPPED WITH A KYSOR AIR OPERATED FAN CLUTCH HAVE A PRESSURE SENSOR INCLUDED IN THE DISCHARGE LINE VEHICLES EQUIPPED WITH A VISCOUS FAN CLUTCH DO NOT REQUIRE A PRESSURE SENSOR IN THE LINE SERVICE PROCEDURE 1 2 Verify the vehicle is applicable and uses an R 12 system Discharge the system using Ford approved methods and a recovery station following the instructions in the appropriate Service Manual Section 12 03 if the system contains a charge Remove the bolts which attach the discharge line to the cooling module by referring to the appropriate Service Manual Section 12 03A For vehicles equipped with an air operated fan clutch remove the wiring connector from the pressure sensor in the discharge line Disconnect the discharge line from the compressor Disconnect the discharge line from the condenser retain the 19E746 A C lock for reuse on the spring lock coupling and discard discharge line Remove the top rear compressor mounting bolt and retain for reuse Install the new discharge line to the compressor while aligning the support bracket with the top left compressor mounting hole When the support bracket is aligned with the mounting hole install the compress
55. G PAINT TO MARK THE LOCATION OF THE SLOT GAP OF THE OLD GOVERNOR LEVER ON THE PUMP SHAFT Mark the injection pump shaft where the lever slot gap is positioned this will be used later to properly position the new lever Figures 1 and 2 Loosen the governor lever pinch bolt and carefully remove the lever from the pump shaft Install the new lever with the slot gap aligned with the paint mark This will position the new lever in the same location as the old lever The spacer located on the pinch bolt in the slot gap of the new governor lever may need to be rotated so that it aligns with the pump shaft This allows the lever to be installed Torque the pinch bolt nut to 90 Ib in 10 2 N m Install the new throttle rod ball stud into the 1 hole on the governor lever the hole closest to the pump shaft Figure 2 Torque the nut 12 17 Ib ft 16 3 23 N m Attach the opposite end of the throttle rod to the accelerator pedal lever Torque the attaching nut to 85 115 Ib in 9 6 13 N m Connect the throttle return spring to the 2 hole middle hole of the governor lever Figure 2 The 3 hole is not used Throttle Adjustment Procedure 14 The throttle adjustment procedure Figure 5 is as follows F B SERIES ACCELERATOR PEDAL STOP BOLT FRONT OF ENGINE 3768 ASSEMBLY Figure 5 Article 95 4 10 a With the accelerator pedal against the stop bolt remove the
56. HAT AIR IS SUPPLIED TO THE FAN CLUTCH DISENGAGING FT WHEN THE TEMPERATURE SWITCH OR THE HIGH PRESSURE SWITCH OPENS THE ELECTRICAL CIRCUIT 15 BROKEN WITHOUT CURRENT THE AIR SOLENOID VALVE CLOSES CUTTING OFF THE AIR SUPPLY TO THE FAN CLUTCH VENTING THE AIR IN THE FAN CLUTCH AND ENGAGING IT IN ADDITION AFTER THE A C HiGH PR SSURE SWITCH RESETS A TIMER WITHIN THE TEMPERATURE SWITCH CASE I8 TRIGGERED WHICH KEEPS THE AIR SOLENOID VALVE DEACTIVATED i a FAN ON FOR THREE MORE MINUTES lap ea un A C JUMPER WIRE HARNESS 190887 WIRE LEAD 14 AJA VEHICLE AIR LINE SUPPLY AIR SOLENOID VALVE 90 120 PSI ESHT 8C 180 AA NORMALLY CLOSED NO CURENT NO AIR VENTS CLUTCH AIR GROUND WHEN IT CLOSES LEAD BLK POWER LEAD R GR 1 4 AIR FUSE WIRE LEAD TO TO INDEX SWITCH AIR SOLENGID A C HIGH PRESSURE SWITCH F3HT 14806 AA NORMALLY CLOSED OPENS 285 PSI RESETS AT 225 PSI TRIGGERS TIMER WHEN IT RESETS CPR 1993 FORD MOTOR COMPANY DEARBORN MICHIGAN 48121 9 93 VALVE BENDIX ON OFF FAN GLUTCH INDEX TEMP TIMER SPRING ENGAGED SWITCH F3H2 10884 G AIR DISENGAGED NORMALLY CLOSED OPENS AT 200 F RESETS AT 192 F STAYS OPEN FOR 3 MINUTES WHEN TRIGGERED BY SWITCH 1 5 63274 SHEET 2 OF 3 ON OFF FAN CONTROL SYSTEM REPLACEMENT KIT F2HZ 8C609 A FOR L 9000 SERIES WITH BENDIX CLUTCH AND AIR CONDITIONING INSTALLATION INSTRUCTIONS TB 3316 B Figure 6 Ar
57. Insert the pin wire from the F4HZ 14A411 A wiring assembly into the 14401 connector Reconnect the connector halves 4 Locate the turn signal flasher If necessary follow the wire from the circuit breaker panel back to the flasher Figure 2 a Remove the flasher from its present location and relocate it to a position next to the circuit breaker panel as shown in Figure 2 b Use the same screws to attach the flasher 5 Cut the wire presently connected to the flasher stud on the circuit breaker panel a the cut wire end b Remove the existing eyelet from the stud and connect the eyelet from the F4HZ 14A411 A wiring assembly 6 Using tie straps and or tape secure the F4HZ 14A411 A wiring assembly to the existing behind the panel harnesses OTHER APPLICABLE ARTICLES NONE SUPERSEDES 94 15 23 WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 201000 201200 203000 203200 95 5 Publication Date MARCH 13 1995 Article No Windshield Wiper New Service Part 95 5 31 MEDIUM HEAVY TRUCK 1980 94 L SERIES ISSUE A wiper arm blade assembly with improved spring durability has been released for service The new wiper arm is the same as the wiper arm that went into production for 1995 except it does not contain the wet arm feature The new arms are black The originals were argent grayish ACTION Replace the current arm blade assembly with F
58. LLOWS THE WHEEL TO ROTATE FREELY WITH 0 001 0 005 0 025 0 127mm END PLAY 9 Install the correct lockwasher for the wheel nut system being used THREE PIECE TANG TYPE LOCKWASHER SYSTEM 1 Install the tang type lockwasher on the spindle NOTE NEVER TIGHTEN THE INNER NUT FOR ALIGNMENT THIS CAN PRELOAD THE BEARING AND CAUSE PREMATURE FAILURE 2 Install the outer nut on the spindle and tighten to 339 N m 250 Ib ft 3 Verify end play Refer to the End Play Verification Procedure in this article 4 After verifying end play secure wheel nuts by bending one 1 of the locking washer tangs over the outer wheel nut and another tang over the inner wheel nut as shown in Figure 8 5 Install a New gasket at axle shaft flange b Axle shaft Axle flange and tighten to specified torque 6 Lubricate axle wheel ends Refer to the Wheel End Lubrication Procedure in this article THREE PIECE DOWEL TYPE LOCKWASHER SYSTEM 1 Install the dowel type lockwasher on the spindle NOTE IF THE DOWEL PIN AND WASHER ARE NOT ALIGNED REMOVE THE WASHER TURN IT OVER AND REINSTALL IF REQUIRED LOOSEN THE INNER NUT JUST ENOUGH FOR ALIGNMENT NEVER TIGHTEN THE INNER NUT FOR ALIGNMENT THIS CAN PRELOAD THE BEARING AND CAUSE PREMATURE FAILURE 2 Install the outer nut on the spindle and tighten to 475 N m 350 Ib ft 3 Verify end play Refer to the End Play Verification Procedure in this article 4 Install a New gasket at axle shaft flange b
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60. Metal e Light colored vehicles Small rust orange dots with black in center of stain e Dark colored vehicles Small white or silver dots with a rainbow hue around the particle The surface will also feel rough to the touch 2 Industrial Fallout e surface feels rough to the touch and may exhibit crystalline deposits Usually ferrous metal is present as well as water spots 3 Acid Rain e Surface will exhibit irregular discolored spotting Dark colored vehicles will show cloudy or greying spots where the acids have started to etch away the paint NOTE IN EXTREME CASES ETCHING OF THE SURFACE WILL BE VISIBLE OR FELT INDUSTRIAL FALLOUT IFO 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 2ND STAGE DAMAGE 15T STAGE DAMAGE CONTAMINATION HAS PENETRATED PAINT FILM DISCOLORATION AND CORROSIVES SPREADING IRON ACID RAIN PARTICLE ENTERING STAINING AND PAINT CORRODING SURFACE CLEAR GOAT OR 3RD STAGE DAMAGE INCORRECT REPAIR PARTICLES CORROSIVE ONLY TOP OF PARTICLE COMPOUNDS CAUSING REMOVED CHEMICAL ETCH SEVERE DAMAGE TO REMOVED PARTICLE AND PAINT S RESIN SYSTEM CORROSIVE COMPOUNDS STILL PRESENT PE 05 Por a i re que WEN A CLEAR COAT OR x pL GE SER pH sase corr 1 Studies conducted
61. N I INSPECTION PROCEDURE e HYDRAULIC LEAK TEST e FLUID LEVEL CHECK HYDRAULIC LEAK TEST 1 With the parking brake applied visually inspect all hydraulic lines connections and hoses for evidence of leaks Replace leaking parts as necessary Specifically inspect the area of the pressure differential valve noting any leakage of fluid from the valve or the switch Inspect the frame rail for missing paint due to valve leakage If leakage is evident go to SECTION II valve replacement This valve is located inside the right frame rail close to the alternator 2 Check the brake piston seals or rear drum brake wheel cylinders for evidence of leaks Replace as needed 3 Inspect all fittings and connections for leaks Tighten fittings and replace O rings as needed FLUID LEVEL CHECK 7 CAUTION FAILURE TO OBSERVE ALL PRECAUTIONS PREVENTING CONTAMINATION OF THE BRAKE SYSTEM WILL RESULT IN DETERIORATION OF RUBBER PARTS LEADING TO REDUCED BRAKE PERFORMANCE With hood open before removing filler caps wipe off the outside of fill cap with a clean dry cloth to prevent contaminants from getting into reservoir when filler caps are removed NOTE THERE ARE TWO 2 MASTER CYLINDERS ON THESE VEHICLES Remove the filler caps from the master cylinder Check and fill if necessary to the level of the bottom of the rings as indicated on the master cylinder reservoir s Use new DOT 3 brake fluid from a sealed container CAUTION NEVER
62. NT AND REAR SPRING EYES AND AT THE SHACKLE BRACKETS ON BOTH SIDES OF THE VEHICLE SIX 6 TOTAL BUSHING LOCATIONS ONE SIDE AT A TIME Place a floor jack under the front axle and raise enough to relieve the weight off the springs Remove the front rear shackle bracket clinch bolts and nuts right and left hand side Remove the shackle pins and shackle brackets and lower the floor jack Support the axle enough to allow access in the shackle area Inspect the bushings to determine if the bushings are the spiral groove type it may be necessary to remove some grease to identify the grooves If the bushing inner surface is smooth replace the bushing with the new spiral groove type bushing Steps 4 7 in this article Inspect the following for wear Shackle brackets and bushings Shackles Spring eye bushings Front hanger brackets The shackles shackle brackets and front spring hanger must be inspected for grooves where parts could come into contact NOTE IF THE FORD APPROVED LUBRICANT WAS NOT USED ON THE VEHICLE THE REMAINING GREASE MUST BE REMOVED AND THEN THE APPROVED LUBE SEE FIGURE 1 MUST BE USED TO PREVENT PREMATURE BREAKDOWN OF THE LUBE SPEC CODE 1 75 S217A 960 C867 A E208A B209A A386A S427A SPEC CODE 901A B 91A FORD LUBE APPROVED SOURCE LIST USA SUPPLIER HAME HEMARKS GREASE GENERAL CHASSIS LONG LIFE LUBRICATION FORD POLYETHYLENE AND MOLYBDENUM DISULFIDE ADDITI
63. NT DAMAGE OR CONTAMINATION 1 Remove a outer bearing and wheel b inner bearing c The oil seal or grease retainer and discard d The old wear sleeve two piece design only with a ball peen hammer and discard CAUTION DO NOT CUT THROUGH THE OLD WEAR SLEEVE DAMAGE TO THE HOUSING MAY RESULT 2 Inspect a The spindle journal and hub for scratches and burrs Recondition with an emery cloth as required NOTE DEEP GOUGES CAN BE REPAIRED BY FILLING GOUGE WITH HARDENING GASKET CEMENT AND THEN SMOOTHING WITH AN EMERY CLOTH 3 Clean a The hub cavity and bearing bores before disassembly Be sure to remove contaminants from all recesses and corners b The bearing thoroughly with solvent and examine for damage Replace damaged or worn bearings 4 Before installation lubricate the following with the same lubricant used in the axle sump a The inner bearing b The wheel seal following the directions provided by the seal supplier NOTE ALWAYS USE THE SEAL INSTALLATION TOOL SPECIFIED BY THE SEAL MANUFACTURER USING AN IMPROPER TOOL CAN DISTORT OR DAMAGE THE SEAL AND CAUSE PREMATURE SEAL FAILURE WHEEL BEARING ADJUSTMENT 1 Identify the wheel nut system being installed Three 3 systems are available a Three piece dowel type wheel nut system Figure 5 THREE PIECE DOWEL TYPE WHEEL NUT SYSTEM INNER NUT P N 119882 OUTER NUT P N 119881 DOWEL PIN DOWEL TYPE LOCKWASHER P N 119883 TB 4308 A
64. O NOT STEAM CLEAN OR HIGH PRESSURE WASH HYDRAULIC STEERING ASSEMBLIES OR FORCE ABUSE CLOSELY FITTED PARTS DAMAGE WILL RESULT 2 Disconnect the power steering pressure and return lines at the gear and drain fluid 3 Disconnect the drag link from the pitman arm 4 Removal of the pitman arm is optional To remove the pitman arm from the sector shaft use Pitman Arm Puller T64P 3590 F 5 Remove intermediate shaft U joint nut and bolt and disconnect it from the steering gear input shaft 6 Disconnect steering gear mounting hardware and remove the gear from the truck s side rail 7 Remove power steering pump per Service Manual Section 13 pre 1993 model years instructions 8 Install Pressure Relief Kit F3HZ 3A561 C per the appropriate Service Manual NOTE REFER TO FIGURE 3 FOR PART USAGE INFORMATION STEERING GEAR CONVERSION CHART CF SERIES MODEL YEARS 1986 THROUGH 1993 12000 LB FRONT AXLES BENDIX C500 TO ROSS TAS65 Lamm ETT MOUNTING HARDWARE 58751 82 1 3 4 10x4 50 GRADE 8 USE C O 58753 52 BOLTS 2 USE NUTS AND WASHERS PITMAN ARM P I A W GEAR F2HZ 3590 D PINCH BOLT NUT BOLT 58750 52 3 4 10x4 25 NUT 34992 52 3 4 10 DRAGLINK F1HT 3304 ABA USE DRAGLINK ATTACHING HARDWARE USE C O HARDWARE POWER STEERING PUMP REMOVE THE POWER STEERING INSTALL PRESSURE RELIEF KIT RELIEF VALVE RELIEF VALVE ASSEMBLY SPRING F3HZ 3A561 C AND SEAL ITEMS 1 2 AND 3 IN FLLUSTRATION BELOW POWE
65. OHZ 19986 A connect the switch to the wiring assembly Reinstall the climate control assembly OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 203000 208000 95 11 Publication Date JUNE 5 1995 Transmission Rockwell RMX9 Overdrive Transmissions Transmission Article No Countershaft End Clearance May Not Be Within Specification Vehicles Built From 95 11 17 411190 Through 1 31 83 Serial Numbers LB9000240 Through LB93001999 MEDIUM HEAVY TRUCK 1990 94 L SERIES This TSB article is being republished in its entirety to revise the affected serial numbers and vehicles ISSUE The transmission countershaft bearing end clearance may not be within specification on some vehicles This could result in an early countershaft bearing concern The affected transmission was installed on Ford vehicles as a DSO option Direct drive and 13 speed transmissions are not involved ACTION Call the Rockwell Customer Service Center Hotline 800 535 5560 USA and Canada for information regarding this program Rockwell Transmission will repair the failed transmissions with factory remanufactured transmissions under warranty For vehicles domiciled in Australia contact Rockwell International located in Sunshine Victoria Australia OTHER APPLICABLE ARTICLES NONE SUPERSEDES 95 6 21 WARRANTY STATUS INFORMATION ONLY OASIS CODES
66. ONE WARRANTY STATUS INFORMATION ONLY OASIS CODES 203000 203200 205000 95 9 Publication Date MAY 8 1995 Battery Cover Rattles Or Cracks Vehicles Equipped With Outboard Frame Mounted Batteries Article No Battery Battery Cover Rattles Or Cracks Vehicles Equipped With Outboard 95 9 12 Frame Mounted Batteries MEDIUM HEAVY TRUCK 1988 95 CARGO SERIES F amp B SERIES L SERIES This TSB is being republished in its entirety to include L Series vehicles with back of cab access package ISSUE The battery box may rattle or crack on some vehicles equipped with outboard frame mounted battery boxes This may be due to the cover latch bracket spoon bending downward and reducing the retention of the latch assembly The reduced retention may allow the battery box cover to rattle which on some vehicles may cause the cover to crack ACTION Install a new more robust latch bracket spoon to the battery box cover in a new location to increase tension If the battery box cover is cracked install a new battery box cover with a new more robust latch bracket installed on the cover Refer to the following Service Procedures for details SERVICE PROCEDURES COVER LOOSE BUT NOT CRACKED 1 Remove the battery box cover drill out the two 2 rivets which retain the spoon to the cover Remove the spoon and discard Install the new Spoon F5HZ 10A784 A using the upper battery cover latch hole as the lower hol
67. OR ALLOWANCE DEALER CODING OASIS CODES 203100 499000 95 17 Publication Date AUGUST 28 1995 Engine Knocking Noise When Operating Engine At 2000 2300 RPM FD1460 Engine Article No FD1460 Engine Knocking Noise When Operating Engine At 2000 2300 RPM 95 17 14 Noise Knocking FD1460 Engine When Operating Engine At 2000 2300 RPM MEDIUM HEAVY TRUCK 1993 95 F SERIES L SERIES ISSUE A knocking noise may be heard coming from the front of the engine when operating at 2000 2300 rpm with a light or no load condition on some vehicles The noise is loudest when the engine is cold and will vary from engine to engine This noise is due to normal acceleration and subsequent contact of the engine timing gears torsional vibration ACTION If the knocking noise is objectionable to the customer replace the current rubber vibration damper with a viscous damper To provide clearance the front engine support must be modified Refer to the following procedure for service details NOTE DUE TO INTERFERENCE ISSUES THIS TSB ARTICLE IS APPLICABLE FOR VEHICLES EQUIPPED WITH EATON VISCOUS FAN CLUTCHES AND F SERIES VEHICLES EQUIPPED WITH 9 5 FRAME TILT HOOD AND KYSOR AIR OPERATED FAN CLUTCHES SERVICE PROCEDURE 1 Verify the engine knocking noise is as described in the ISSUE Section of this article 2 Remove the main drive belt 3 Remove the crankshaft pulley adapter damper Refer to the appropriat
68. R STEERING HOSES E7HU 34719 BA F1HT 34719 ZA 1985 TO 1990 MY HOSE FITTINGS USE C O FITTINGS WHERE APPLICABLE OTHERWISE USE 384074 536 1 2 HOSE 37 FLARE 3 4 STD THD 390536 57 NIPPLE 1 2 HOSE 3 4 16 O RING ESHT 3E599 BA 90 ELBOW Figure 3 Article 95 15 15 Ross Gear Installation 1 Install the power steering pump with the revised relief valve per the appropriate Service Manual NOTE THAT A NEW HIGHER PRESSURE PUMP IS REQUIRED BECAUSE THE ROSS TAS65 GEAR USES A HIGHER PRESSURE SYSTEM 150 BAR VS 140 BAR FOR BENDIX GEAR Place the gear on the side rail and install the nuts and bolts Torque bolts to 299 406 N m 220 300 Ib ft Install intermediate shaft U joint onto the steering gear input shaft Torque bolts to 68 95 N m 50 70 lb ft Place the pitman arm on the steering gear sector shaft and align the arm s notch with the notch on the end of the sector shaft Use a chisel to spread the pitman arm to slide onto the sector shaft WARNING DO NOT USE A HAMMER TO FORCE THE PITMAN ARM ONTO THE SECTOR SHAFT THIS COULD DAMAGE SECTOR SHAFT BEARINGS AND CAUSE LOSS OF GEAR PRELOAD Install arm pitch bolt and nut Torque nut to 299 406 N m 220 300 Ib ft Attach pitman arm to drag link Torque to 150 204 N m 111 151 Ib ft Insert cotter pin Install the pressure and return lines to the gear and pump TAKE CARE NOT TO CRIMP THE LINES Fill the reservoir with Motorcraft MERCON Multi Purpose
69. SERVICE PROCEDURE 1 Remove the front mount bolts and threaded spacer and discard 2 Jack up the engine enough to remove the existing insulators and spacer plates if provided and discard 3 Position the new spacers and isolators in place as described on the appropriate sketch Refer to Figures 1 2 and 3 ALL CF SERIES AND FB SERIES MODELS WITH 9 1 2 FRAME AND FD1060 1450 DIESEL ENGINE VIEW FRONT MOUNT 34989 52 NUT 2 REQUIRED WASHER Pee ron OF VEHICLE 2 REQUIRED INSULATOR ASSEMBLY FRONT F4H2 6A027 B 2 REQUIRED SPACER PLATE FRONT 2 PIEGES ONE ABOVE AND ONE BELOW CROSSMEMBER F4HT 6B095 DA SPACER FRONT MOUNT 2 REQUIRED 58687 92 44879 52 BOLT WASHER 2 REQUIRED 2 REQUIRED TB 3245 B Figure 1 Article 95 23 15 ALL F B SERIES MODELS WITH 9 1 2 FRAME AND FD1060 1460 DIESEL ENGINE 34989 52 2 REQUIRED VIEW B FRONT MOUNT 44879 52 WASHER F4HT 6038 AA 2 REQUIRED INSULATOR ASSEMBLY FRONT 2 REQUIRED An OF VEHICLE FAHZ 6AQ27 A SPACER PLATE FRONT F4HZ 6A027 B SPACER PLATE FRONT BELOW CROSSMEMBER F4HT 6B095 BA 44879 52 MD SPACER FRONT MOUNT WASHER 2 REQUIRED 2 REQUIRED 58689 52 BOLT 2 REQUIRED TB 3246 B Figure 2 Article 95 23 15 ALL L SERIES MODELS WITH FD1060 1460 DIESEL ENGINE 34889 52 NUT 2 REQUIRED VIEW FRONT MOUNT o ee ENGINE BLOCK
70. SUE 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 to complete the installation The Wiring Kit 14A411 consists of e One 1 Wiring and Connector Assembly e Seven 7 5 16 8mm Heat Shrink Tubing 2 51mm long e 1 37 63 lead tin Solder 0 032 0 80mm diameter x 12 305mm long e One 1 Adhesive Label e Instruction Sheets Not included in the kit is the Wiper Motor 17508 OTHER APPLICABLE ARTICLES NONE SUPERSEDES 94 11 20 95 4 6 WARRANTY STATUS INFORMATION ONLY OASIS CODES 202000 95 8 Publication Date APRIL 24 1995 Radio Two Way Radio Reduced Operating Range Vehicles With Allison World Article No Transmission MD And HD Series 95 8 10 MEDIUM HEAVY TRUCK 1993 95 CARGO SERIES F SERIES L SERIES
71. T 4 Mark the injection pump shaft where the lever slot gap is positioned this will be used later to properly position the new lever Figures 1 and 2 NEW LEVER SPACER WITH FLAT SPOT HOLE 1 HOLE 2 HOLE 3 TB 3765 A Figure 2 Article 95 4 10 5 6 10 11 Loosen the governor lever pinch bolt and carefully remove the lever from the pump shaft Install the new lever with the slot gap aligned with the paint mark This will position the new lever in the same location as the old lever The spacer located on the pinch bolt in the slot gap of the new governor lever may need to be rotated so that it aligns with the pump shaft This allows the lever to be installed Torque the pinch bolt nut to 90 Ib in 10 2 N m Install the new throttle rod ball stud into the 1 hole on the governor lever the hole closest to the pump shaft Figure 2 Torque the nut 12 17 Ib ft 16 3 23 N m Connect the throttle return spring to the 2 hole middle hole of the governor lever Figure 2 The 3 hole is not used Throttle Adjustment Procedure 12 The throttle adjustment procedure Figure 4 is as follows L SERIES ACCELERATOR EDAL ROAD DRAFT TUBE REF ENGINE amp TB 3767 A Figure 4 Article 95 4 10 a b C d With the accelerator pedal against the stop bolt adjust the throttle rod so the fuel injection pump throttle lever is at full throttle wide open thrott
72. T 15 BROKEN WITHOUT CURRENT THE SOLENOID VALVE CLOSES CUTTING OFF THE AIR SUPPLY TO THE FAN CLUTCH VENTING THE AIR IN THE FAN CLUTCH AND ENGAGING IT 1 4 AIR VEHICLE AIR LINE SUPPLY AIR SOLENOID VALVE BATTERY 20 120 PSI E9HT 8C 180 AA 12 VOLTS NORMALLY CLOSED NO CURRENT NO AIR VENTS CLUTCH AJA GROUND WHEN IT CLOSES LEAD Aip BLK POWER LEAD R GR AIG JUMPER WIRE 1 4 HARNESS 190887 FUSE LINE WIRE LEAD WIRE LEAD TO TO INDEX SWITCH m AIR SOLENOID op JUMPER PLUG CONNECTOR P F3HT 14370 AA LII USED ON THE WIRE LEAD TO AAG SWITCH ON NON A C VEHICLES BENDIX ON OFF FAN CLUTCH CLOSES A C CIRCUIT INDEX TEMP TIMER SPRING ENGAGED SWITCH 2 10884 AIR DISENGAGED NORMALLY CLOSED OPENS AT 200 F RESETS AT 192 F TIMER WILL NOT BE ACTIVATED WHEN THE JUMPER FLUG IS USED FIGURE 1 1 5 63284 SHEET 2 OF 3 CPR 1903 FORD MOTOR COMPANY ON OFF FAN CONTROL SYSTEM REPLACEMENT DEARBORN MICHIGAN 48121 KIT F2HZ 8C609 B FOR L 9000 SERIES WITH 9 03 BENDIX CLUTCH W O AIR CONDITIONING INSTALLATION INSTRUCTIONS TB 3319 8 Figure 9 Article 95 25 14 HARNESS INSTALLATION SOLENOID AIR VALVE F3HT 14370 AA JUMPER PLUG ON VEHICLES WITHOUT A C 778 7777 DEF ENGINE REFERENCE FIGURE 2 TYPICAL AIR LINE INSTALLATION AND ROUTING CONNECTORS SOLENOID AIR VALVE 174 Q D TUBE SOLENCID
73. T BOTTOM PUSH PULL AT SIDES OF DRUM END PLAY ADJUSTMENT END PLAY ADJUSTMENT WITH TIRE AND WHEEL ASSEMBLY WITH WHEEL HUB TB 4313 A Figure 10 Article 95 15 16 3 A Adjust the dial indicator so that its plunger or pointer is against the end of the spindle with its line of action approximately parallel to the axis of the spindle 4 Grasp the wheel assembly at the o clock and 9 o clock positions Push the wheel assembly in and out while oscillating it to seat the bearings Read bearing end play as the total indicator movement 5 f end play is not in specification readjustment is required Refer to the End Play Readjustment Procedure in this article END PLAY READJUSTMENT PROCEDURE EXCESSIVE END PLAY If the end play is greater than 0 005 0 127mm remove the outer nut and pull the lockwasher away from the inner nut but not off the spindle Tighten the inner nut to the next alignment hole of the dowel type washer if used Reassemble the washer and retorque the outer nut Verify end play with a dial indicator INSUFFICIENT END PLAY If the end play is not present remove the outer nut and pull the lockwasher away from the inner nut but not off the spindle Loosen the inner nut to the next alignment hole of the dowel type washer if used Reassemble the washer and retorque the outer nut Verify end play with a dial indicator FINE TUNING END PLAY If after performing the readjustment procedures end play is stil
74. TATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 208000 208999 Bulletin Contents TSB Article 95 3 24 has been superseded by Article 95 15 17 95 3 Publication Date FEBRUARY 13 1995 Glass Corrosion From Windshield Weatherstrip Scraping Paint Off Surrounding Body Surface Vehicles Built Before 8 31 94 Service Tip Article No Paint Corrosion From Windshield Weatherstrip Scraping Paint Off Surrounding 95 3 26 Body Surface Vehicles Built Before 8 31 94 Service Tip MEDIUM HEAVY TRUCK 1970 95 L SERIES ISSUE Some trucks may have paint scraped from the body surfaces directly in contact with the windshield weatherstrip causing corrosion This is due to normal movement of the windshield weatherstrip which scrapes the paint from the windshield opening flange ACTION A resolution using a urethane film between the windshield weatherstrip and the opening flange has been developed It has been used in production beginning in August 1994 Refer to the following procedure for service details SERVICE PROCEDURE 1 Remove windshield and weatherstrip and hold for reinstallation if possible Refer to the appropriate L Series Service Manual and Section 2 Repair rusted sections including application of primer and topcoat a Remove corrosion from sheet metal sections using sanding or blasting methods b Use appropriate methods to cover exposed interior and exter
75. USE BRAKE FLUID WHICH HAS BEEN DRAINED FROM THE HYDRAULIC SYSTEM OR THAT HAS BEEN STORED IN AN OPEN CONTAINER Replace the master cylinder filler caps SECTION II PRESSURE DIFFERENTIAL VALVE ASSEMBLY DIAGNOSTIC AND REPLACEMENT BRAKE WARNING LAMP SYSTEM TEST NOTE WHEN BOTH BRAKE SYSTEMS ARE FUNCTIONING NORMALLY EQUAL PRESSURE ON BOTH SIDES OF THE PRESSURE DIFFERENTIAL VALVE WILL KEEP THE VALVE CENTERED DURING BRAKE PEDAL APPLICATION THE BRAKE WARNING LAMP WILL ILLUMINATE ONLY WHEN THE IGNITION KEY IS IN THE START POSITION AND WILL GO OUT AFTER APPROXIMATELY 1 2 SECOND 1 Turn the ignition switch to ACC or ON The red brake warning lamp should be off If the lamp remains on go to Step 7 Turn the ignition switch to start The warning lamp should illuminate for approximately 1 2 second If the red brake warning lamp does not illuminate check the lamp bulb and replace if necessary then recheck If lamp illuminates and flashes for approximately 1 2 second and then goes out the warning system is functioning properly go to SECTION III If not continue with next step If the brake warning lamp still does not illuminate after the bulb has been replaced simulate pressure not being equal in both brake systems by disconnecting the red secondary delivery line on the foot valve Figure 2 Item 1 Apply and release the brakes This should cause the piston in the valve to shuttle over and make contact with the switch causing the lamp to c
76. VES SHELL CO USES 70377 EXXON CO USA CONOCO INC SATTENFELD GREASE AND OIL GORP DIST KENDALL REFINING SURBOND LUBRICANTS BATTEN FELT AMERICA AMOCO OIL CO SOUTHWEST PETRO CHEMICAL INC CANADA SUPPLIER NAME REMARKS SURBOND LUBRICANTS LTD BATTENFELD GREASE CANADA LTD DIST WOBBISH SURBOND LUBRICANTS LTD MIG75 B TB 3592 A TRADE NAME CODE MOTORCRAFT XG 1 C SHELL LITHIUM MOLY POLY 5160 6897 158 B 175 B BA 175 B LG 1007 SA 8279132 IBADE NAME CODE 42 M MIC75 B Figure 1 Article 95 12 11 CAUTION MIXING INCOMPATIBLE LUBRICANTS WILL CAUSE EITHER SOLIDIFICATION OR LIQUIFICATION OF THE LUBE MIXTURE NOTE USE ONLY FORD APPROVED LUBE XG 1 C PREFERRED OTHER LUBES HAVE NOT PERFORMED ACCEPTABLY IN THIS APPLICATION THE RECOMMENDED LUBE SERVICE INTERVAL IS EVERY 6000 MILES 9660 KM SERVICE PROCEDURE If the bushings are worn or found to be the old design install new Spiral Groove Bushings F2HZ 5348 A in all three 3 connections according to the following procedure Use the special service tools listed below e 139 00100 Rotunda Spring Shackle Repair Kit D94T 3110 B Non Expanding Arbor D94T 3110 C Expanding Arbor 1 Using the non expanding arbor tool D94T 3110 B and a large C clamp press out the old shackle bracket bushing 2 Using the expanding arbor tool D94T 3110 C and a large C clamp press the old bushings out of t
77. ball stud from the accelerator pedal blade b Adjust the rod so the fuel injection pump throttle lever is at full throttle wide open throttle c Increase the length of the rod assembly until approximately 1 16 of break over is achieved in the throttle lever d Tighten the jam nuts Final Inspection 15 The final inspection steps are as follows a Once the new parts have been installed and attaching nuts torqued properly check the operation of the accelerator pedal and linkage to ensure it works easily and returns properly b The pedal must return completely from wide open throttle without any drag or binding c surrounding engine compartment components hoses wiring etc may contact any moving part of the accelerator controls d If the vehicle is equipped with a hand throttle check the throttle handle for flushness with the dash panel when engine is at idle Adjust if required NOTE THE NEW GOVERNOR LEVER DOES NOT HAVE AN INDEXING FEATURE THEREFORE FOR ANY FUTURE FUEL INJECTION PUMP OR LINKAGE REPAIR THAT REQUIRES REMOVAL OR REPLACEMENT OF THE GOVERNOR LEVER IT WILL BE NECESSARY TO NOTE AND OR MARK THE LOCATION OF THE LEVER SO THAT IT CAN BE REINSTALLED IN THE CORRECT POSITION OLD LEVER ASSEMBLY 9 GOVERNOR LEVER ASSEMBLY INJECTOR PLIMP THROTTLE ROD y THROTTLE RETURN SPRING gt TB 3766 A Figure 3 Article 95 4 10 SUPERSEDES 95 2 13 W
78. by the A C high pressure switch prevents unstable air conditioning compressor pressure inputs from cycling the fan clutch excessively Air line routing to the fan clutch is simplified A new wire harness is used to join the Temp Timer switch the A C high pressure override switch and the air solenoid valve NOTE ALL VEHICLES WITH OR WITHOUT A C REQUIRE AN A C JUMPER HARNESS NOT INCLUDED IN KIT IN ADDITION VEHICLES WITHOUT A C USE A SPECIAL JUMPER PLUG INCLUDED IN KIT AT THE A C PRESSURE SWITCH CONNECTOR REFER TO INSTRUCTION SHEET 6328A FOR NON A C VEHICLES FIGURES 8 THROUGH 10 FAN DRIVES SYMPTOMS AND DIAGNOSIS Typical symptoms of the Bendix fan drive when subjected to faulty controls are e Smoke from the clutch as it is engaging e _ Blistered paint on the exterior of the cone surface e Blued exterior cone surface X Air leaks due to heat hardening of the O ring seals X Excessive lining wear at 480 000 km 300 000 miles the fan clutch cone should extend not more than 3 175mm 1 8 over its mating hub indicating 50 lining wear At 100 lining wear the cone will extend 6 35mm 1 4 over the hub and the clutch will no longer engage CAUSAL FACTORS A slowly exhausting control system may be due to Kinked air line s Overcrimped fitting s Deteriorating control valve one that exhausts slowly leaks or traps air pressure Contaminated clogged air solenoid valve Anything that restricts the air from exhaust
79. ctronic modules 2 routing should be done to maintain a great distance between vehicle wiring and the feedline ANTENNA TUNING It is important that the antenna be tuned properly and reflected power be kept to less than 10 VSWR less than 2 1 RADIO WIRING AND CONNECTION LOCATIONS 1 Both transreceiver power lead connections should be made directly to the battery For one piece transreceivers where the ignition switch is desired a 12 volt contactor should be located at the vehicle battery with the coil of the contactor driven through an appropriate in line fuse from an available ignition switch circuit which is not powered during cranking Complete the contactor coil circuit by returning to battery negative 2 Any negative lead from a handset or control unit must return to battery negative It is preferable that the positive lead for a handset or control unit positive and negative leads be appropriately fused separately from the transreceiver positive and negative leads WIRE ROUTING The power and ground connections should be routed through the vehicle as far away as possible from any electronic modules TROUBLESHOOTING Possible causes of unwanted vehicle RFI include a b C d Power leads connected to points other than the battery Antenna location Transreceiver wiring located too close to vehicle electronics Poor shielding or poor connections on antenna feed line OTHER APPLICABLE ARTICLES N
80. dentification line as a visual check for correct insertion Lines on all the tubes should not be visible if properly inserted 7 Reinstall the control assembly in the dash panel using the previous steps in reverse order OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 208000 208100 208200 208300 208999 95 5 Publication Date MARCH 13 1995 Turn Signal Or Turn Signal Hazard Flasher Inoperative When Flasher Circuit Is Overloaded Vehicles With Hobbs Heavy Duty Flasher And Fleet Or Full Article No Instrumentation 95 5 30 Wiring Upgrade Of Wiring And Components For Increased Flasher Circuit Capacity Vehicles With Hobbs Heavy Duty Flasher And Fleet Or Full Instrumentation MEDIUM HEAVY TRUCK 1987 94 L SERIES This TSB is being republished in it entirety to update the parts listings ISSUE The turn signal and hazard warning flasher may become inoperative if the flasher circuit is overloaded ACTION Install an improved overlay type harness which provides additional flasher circuit capacity by replacing the existing 14 gauge circuit in the 14401 wiring assembly with a 10 gauge wire and an improved connector This wiring assembly also allows relocation of the flasher from under the instrument panel to a more accessible location in the circuit breaker panel area Refer to the following procedure for service details 1 L
81. dicator If runout exceeds 0 020 replace the pulley and recheck runout EK COMPRESSOR PULLEY ALIGNMENT WITH HARMONIC BALANCER PULLEY BEFORE REPLACING IDLER BRACKET ASSEMBLY MAKE ADJUSTMENTS AS NECESSARY 3 Remove the single pulley idler assembly 4 Install the new dual pulley idler assembly E8HZ 19K603 A 5 Reinstall the A C drive belt replace if worn 6 Run the engine for 10 15 minutes to allow the belt to stretch 7 Readjust the drive belt OTHER APPLICABLE ARTICLES NONE SUPERSEDES 95 10 17 WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 208000 208200 95 14 Publication Date JULY 17 1995 Noise Vibration Transmitted Through Non Isolated Shift Tower Lever DSO Rockwell Transmission Vehicles Built Before 11 29 93 Article No Transmission DSO Rockwell Noise And Vibration Transmitted Through 95 14 14 Non Isolated Shift Tower Lever Vehicles Built Before 11 29 93 MEDIUM HEAVY TRUCK 1990 94 L SERIES ISSUE Objectionable noise or vibration may be transmitted through the shift tower lever into the cab on some L Series vehicles This is caused by the lack of isolation on the shift lever ACTION Install an isolated shift tower lever to the current transmission Refer to the following Service Procedure for details SERVICE PROCEDURE 1 Remove the shift knob including the air lines for the shift selector making note of their
82. dure for details SERVICE PROCEDURE 1 Confirm that this metal contact is the cause of the concern a Remove the lower engine mount isolator and spacers b Check the spacers for signs of contact with the crossmember A shiny spot on the spacer indicates contact 2 If contact has occurred support the front of the engine and remove the upper engine mount isolator 3 Widen the hole in the front engine crossmember from 36mm 1 4 wide to 41mm 1 6 wide with a small die grinder Refer to Figure 1 SPAGER CONTACT AREA CROSSMEMBER CONTACT AREA S LOWER ISOLATOR i 36mm 1 4 REMOVE MATERIAL TB 2856 B Figure 1 Article 95 23 16 OTHER APPLICABLE ARTICLES NONE SUPERSEDES 92 25 19 WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 304000 305000 702000 702100 703000 Bulletin Contents TSB Article 95 24 10 has been superseded by Article 96 10 18 Bulletin Contents TSB Article 95 24 11 has been superseded by Article 96 10 21 Bulletin Contents TSB Article 95 25 3 has been superseded by Article 97 19 10 95 25 Publication Date DECEMBER 18 1995 Fan Clutch Bendix Availability Of New On Off Control System Kits For Improved Durability L 9000 Series Vehicles Built Before 11 29 93 Article No Fan Clutch Excessive Wear L 9000 With Bendix Fan Clutch Vehicl
83. e bolts to 75 105 Ib ft 102 142 N m TB 4338 A Figure 1 Article 95 18 14 2 Install bracket Figure 1 Item 4 onto the engine using two 2 bolts and washers Figure 1 Items 5 and 6 Torque the bolts to 75 105 Ib ft 102 142 N m 3 Install the attaching bolts and washers Figure 1 Items 7 and 8 between the two 2 brackets as shown Torque to 75 105 lb ft 102 142 N m 4 Install the remaining components by referring to the 1995 L Series Powertrain Drivetrain Service Manual Section 03C 05 OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 402000 497000 499000 95 19 Publication Date SEPTEMBER 25 1995 Article No Hood Separation Between Headlamps And Grille 95 19 16 MEDIUM HEAVY TRUCK 1985 95 L SERIES ISSUE The hood may separate between the headlamps and grille on some vehicles operating in severe duty conditions A revised design hood was placed in production on 8 2 95 to reduce the possibility of separation ACTION If vehicles exhibit this concern install a replacement hood which has added reinforcement to reduce the possibility of separation Refer to the following Service Procedure for details SERVICE PROCEDURE 1 Remove the hood refer to the appropriate L Series Service Manual Section 01 02 for details 2 Remove and install all items that are to be transferred to the new
84. e model year Service Manual Section 03B 01 4 Before the new viscous damper can be installed the front engine support will have to be modified This involves removing a portion of the front engine support center rib Figure 1 This can be performed with the engine support on the vehicle REMOVE THIS PORTION OF THE RIB FRONT ENGINE MOUNT F3HZ 6028 B IF BRACKET IS ACCIDENTLY CUT BEYOND THE DIMENSIONS SHOWN IN FIGURE 2 IT MUST BE REPLACED WITH A NEW REWORKED PART 4235 Figure 1 Article 95 17 14 5 Mark the center rib of the front engine support to the dimensions shown in Figure 2 SCRIBE LINE IN CENTER WEB IN EACH LOCATION SHOWN CONNECT AS SHOWN WITH THE DOTTED LINE HEMOVE CROSSHATCHED AREA Figure 2 Article 95 17 14 CROSS SECTION OF FRONT ENGINE SUPPORT tomm 0 397 24 8mm 0 93 TO RADIUS 6 35mm 0 25 RADIUS a 0mm D 08 SURFACE TO BE SMOOTH AND FREE OF TOOL MARKS 4236 6 Using a die grinder with an aluminum cutting bit carefully remove the marked portion of the center rib material NOTE IF THE BRACKET IS CUT BEYOND THE DIMENSIONS SHOWN IT MUST BE REPLACED WITH A NEW REWORKED BRACKET F3HZ 6028 B 7 When grinding is complete the ground surface must be smoothed free of tool marks Clean the area thoroughly 8 Lubricate the threads of four 4 new 3914118 CF capscrews Cummins 3914118 with 15W40 engine oil NOTE
85. e on the new latch This will raise the position of the spoon location on the box cover Install the spoon using one 1 1 4x1 2 Blind Pop Rivet 372820 S36 or equivalent as described in Step 2 Properly align the spoon on the box cover and drill out the new top hole location in the box cover through the spoon Install the Upper Pop Rivet 372820 S36 or equivalent and reinstall the cover to the battery box BATTERY BOX COVER CRACKED 1 For vehicles with cracked cover anew cover assembly may be installed Refer to the following Battery Box Application Chart for the proper application Remove the old cover assembly and replace it with a new cover assembly The new cover will include the new latch in the revised location OTHER APPLICABLE ARTICLES NONE SUPERSEDES 95 6 20 WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 203000 305000 95 9 Publication Date MAY 8 1995 Reduced Power Vehicles With FD1060 190 Horsepower Engine And Allison Article No Automatic Transmission 95 9 13 MEDIUM HEAVY TRUCK 1992 94 CARGO SERIES F amp B SERIES L SERIES ISSUE Some vehicles equipped with FD1060 engine 190 Horsepower and Allison Automatic Transmission may exhibit reduced power even after performing TSB 94 3 11 This may be due to the use of a non wastegated turbocharger on these engines ACTION If after performing TSB 94 3 11 a reduced power conc
86. ed Dot Red Dot Corporation P O Box 58270 Seattle Washington 98138 Telephone 206 575 3840 IN CAB KYSOR KA700 SIDEKICK A C UNITS Existing R 12 KA700 units can be made R 134a compatible by replacing the Thermal Expansion Valve TXV The KA700 R 12 TXV Kysor part number 404098 should be replaced with a Kysor R 134a TXV part number 404255 available directly from Kysor Kysor Westran 602 East Blackhawk Drive Byron Illinois 61010 0921 Telephone 815 234 2811 OTHER APPLICABLE ARTICLES 93 5 16 WARRANTY STATUS INFORMATION ONLY OASIS CODES 208000 208200 Bulletin Contents TSB Article 95 10 17 has been superseded by Article 95 13 9 95 10 Publication Date MAY 22 1995 Article No 95 10 18 Engine FD1060 Diesel Crankshaft Damper Service Parts Clarification MEDIUM HEAVY TRUCK 1992 95 CARGO SERIES F amp B SERIES L SERIES ISSUE There may be some concerns over the correct part application regarding FD1060 Diesel engine crankshaft dampers This article provides the correct part applications and identification ACTION If service is required for the FD1060 engine install the correct part per the Application Chart Refer to the following for correct applications PRODUCTION AND SERVICE PART APPLICATION The FD1060 engine can use either a rubber or viscous crankshaft damper depending on the type of transmission that is used All vehicles equipped with the Allison AT 545 automa
87. eeve 383800 5 and nut 386478 5 forms 2B418 part NOTE Application on LN LNT models requires A C Jumper Wire Assembly F3HT 19D687 BA Application on LS LTS L LT LA LTA models requires A C Jumper Wire Assembly F3HT 19D387 CA Application on LLS LTLS LL LLA LTLA LTL models requires A C Jumper Wire Assembly F3HT 19D887 DA The A C Jumper Wire Assembly 19D887 is not included in kit INSTRUCTIONS 1 Remove the Kysor fan stat 8K612 from its port naar the front of the engine location varies identify the location by tracing the air line from the clutch When removing the Kysor fan stat 8K612 from its port near the front of the engine also remove the 1 2 pipe fitting If this is not removed damage to the Index Temp Timer may occur Engine coolant may need to be drained to the level of the port Insert the Index Temp Timer switch F3HZ 10884 C into the open port The threads on the 10B843 are pre coated with sealant Torque to 25 Ft Lbs 2 Replace existing A C high pressure switch and O Ring 14806 and 379737 5 with those included in the kit 3 Remove the A C jumper wire harness 19D887 connecting the A C high pressure switch 14806 to the air solenoid valve BC180 Replace it with the appropriate wire hamess 19D887 not included in kit The new wire harness attaches to power ground A C high pressure override switch 14806 Temp Timer switch 10B843 and air solenoid valve 8 180 See Figures 1 and
88. enoid air valve to air manifold ta 1t 1 4 Air Line 83 Length solenoid air valve to fan clutch a 1 9058 BwdmgSmp t 5 a NOTE Bulk tubing D6TA 2B417 AE cut to length and fitted at both ends with sleeve 383800 S and nut 386478 5 forms 2B418 part NOTE Application on LWLNT models requires A C Jumper Wire Assembly F3HT 19D887 BA Application on LS LTS L LT LA LTA models requires A C Jumper Wire Assembly F3HT 19D887 CA Application on LLS LTLS LL LLA LTLA LTL models requires Jumper Wire Assembly F3HT 19D887 DA The A C Jumper Wire Assembly 19D887 is nat included in kit INSTRUCTIONS 1 Remove the Kysor fan stat 8K612 from its port near the front of the engine location varies identify tha location by tracing the air line from the clutch When removing the Kysor fan stat 8K612 from its port near the front of the engine also remove the 1 2 pipe fitting H this is not removed damage to the index Temp Timer may occur Engine coolant may need to be drained to the level of the port Insert the Index Temp Timer switch F3HZ 10884 C into the open port The threads on the 10B843 are pre coated with sealant Torque to 25 Ft Lbs Install the air solenoid valve BCt80 and attaching brackets See Figure 3 Detail Z Install the jumper plug connector 14370 on the wire lead to the A C high pressure switch on the wire hamess 19D887 not included in kit Strap that part of the wire a
89. erine C C N cm Boss Fasem 548 250 rnuersi 2065 CM ighi Saddle CIC oz sos ses sto Fouer 7908 mue oz 8756 CodwanGCA N Fz soe Bee Fass rz 50627 7VERB Torsador Red Tint 80663 FASEJB 512301 26149 33056 JB 5099 89695 49762 7VESB poses 52 2660 Fouere 4 23 676 merecia N vs stor fases _ 512 2062 eo n ur 50 Bees 527 amsa rouez2 wwe sess ur 6763 Med Wedgewood C C amp N Baer Fagin 828 20154 rmuszea 50 Pacmeareencica N PS 50 Bo 529 26155 676 so 5 Fasso 520 2656 roweree 7090 so Alpine Green C C N on su mee uev mu 58 6771 Dark Toreador CIC N Ben Fagsur 522 z9 7vwse 33055 UF ers N m se Bes soars sos rouws774 120 78 796 N wo esn sisi 28176 20067 90 58 6797 DarkToumaimecica N NB sus Boze 584 26 74 FDU 6Te7 61834 NB 67 Foya Blue N LE suz Fasie sie 2073 ouem samme 52 LE TeresdorredMet cica FN 58 Bom Fasern s85 26072 salen aus FM 6201
90. ern still exists replace the non wastegated turbocharger with a wastegated turbocharger Refer to the following Service Procedure for details SERVICE PROCEDURE 1 Verify the vehicle complies with the concern description engine horsepower and model year Follow the service procedures outlined in TSB 94 3 11 If the reduced power concern still exists proceed to Step 2 2 Visually inspect the turbocharger and verify it is wastegated Item 9 in Figure 1 shows the wastegate actuator diaphragm If the turbocharger is not wastegated replace the turbocharger with a wastegated Turbocharger F3HZ 6K682 ARM Refer to the appropriate Service Manual Section 03A 04B for removal and installation procedures The new turbocharger comes with a new mounting gasket studs and nuts Additionally an Oil Return Line Gasket F3HZ 6N652 B is required WASTEGATE ACTUATOR DIAPHRAGM TB 4222 Figure 1 Article 95 9 13 OTHER APPLICABLE ARTICLES 94 3 11 WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 614000 614500 95 9 Publication Date MAY 8 1995 Article No Caterpillar 3406 PEEC Main Drive Belt Rolls Off Fan Drive Belt Misalignment 95 9 14 MEDIUM HEAVY TRUCK 1994 95 L SERIES ISSUE The main drive belt may experience early wear and or the drive belt may roll off the fan hub on some vehicles This may be due to an interference between the fan hub mount
91. es Built Before 95 25 14 11 29 93 MEDIUM HEAVY TRUCK 1988 94 L SERIES This TSB article is being republished in its entirety to update model year coverage ISSUE Early failure of the fan clutch in certain operating conditions may be due to the relatively slow response engagement of the current fan clutch control system ACTION Install a new ON OFF fan clutch control system kit The new ON OFF control system extends the life of the fan clutch by engaging it more rapidly Refer to revised Instruction Sheets 463274 Figures 5 6 and 7 or 6328A Figures 8 9 and 10 for A C or non A C shown in this TSB article for installation details ON OFF FAN CONTROL SYSTEM REPLACEMENT KIT F2HZ 8C609 A FOR L 9000 SERIES WITH BENDIX CLUTCH AND AIR CONDITIONING INSTALLATION INSTRUCTIONS Kit Contents Part Number F2HZ 8C609 A Description Index Temperature Timer High Pressure Switch O Ring Seal a Solenoid Air Valve b 1 4 Air inlet Adapter D5TA 2B418 AE0330 1 4 Air Line 83 Length solenoid air valve to fan clutch c Bundling Strap 4 Instruction Sheet a NOTE O Ring is used on the A C high pressure line at the high pressure switch port b NOTE For pre 1989 vehicles with air conditioning check the part number on the air solenoid valve B8C180 If it does not have an ESHT prefix replace the valve with one that does c NOTE Bulk tubing DETA 2B417 AE cut to length and fitted at both ends with sl
92. essary to repeat each of the above steps NOTE THE NEUTRALIZER CONCENTRATE IS A HEAVY DUTY SHAMPOO AND CAN BE USED IN AN AUTOMATIC CAR WASH SYSTEM CORRECTION OF SURFACE FOLLOWING DECONTAMINATION 1 Visually inspect surface for evidence of removal of ferrous metal particles crystalline deposits water spots Acid rain discoloring or etching will require either buffing color sanding or refinishing if etching is visible Use the buffing products from only one 1 manufacturer Do not intermix products Always follow the manufacturer s product sequence Use appropriate pads with each product as recommended by the manufacturer NOTE DO NOT REMOVE MORE THAN 0 3 OF A MIL OF PAINT MATERIAL OR REPAINTING WILL BE REQUIRED Use a dual action sander D A Sander with a velcro mount backing plate and appropriate foam pad for final polishing swirl removal Use an alcohol and water mixture 1 4 ratio to clean buffed areas to verify removal of scratches and swirls before application of final protective glaze NOTE FREQUENT WASHING OF VEHICLES IS IMPORTANT CONTAMINANTS SETTLE ONTO THE VEHICLE EVERY DAY USE CLEAN WATER DEIONIZED REVERSE OSMOSIS ETC TWICE WEEKLY TO REMOVE HEAVY DUST AND PARTICULATES THE USE OF A NEUTRAL pH CAR WASH SOAP EVERY TWO 2 WEEKS IS RECOMMENDED TO NEUTRALIZE VEHICLE CONTAMINATION NOTE DEALERS SHOULD USE PROGRAM CODE R 23 AND CONDITION CODE C5 AND C6 REFER TO W amp P MANUAL SECTION 5 1 PAGE
93. ew gear housing F3HZ 6019 J 4 If it is not already plugged plug the upper dowel hole in the gear housing Refer to Figure 1 Install a dowel pin 3900257 CF using Loctite 227 The dowel pin should be inserted until it is just below the surface of the gear housing that faces the gear cover Figure 1 Article 95 15 17 5 Install the gear housing gasket F2HZ 6020 AA and the gear housing Use the new Loctite coated bolts 3926846 CF and torque to 35 N m 26 Ib ft Refer to Figure 5 GEAR HOUSING LOCATION OF FIVE 5 SHORT BOLTS Figure 5 Article 95 15 17 6 Install camshaft air compressor fuel injection pump valve tappets push rods rocker lever assemblies and valve covers Use two 2 new N807763 S43B studs in the gear housing for the air compressor mounting Use Loctite 277 on the studs and install the studs into the gear housing to the shoulder of the stud Install the air compressor mounting gasket F3HZ 3K506 C Install the compressor using two 2 new hex flanged torque prevailing nuts N620483 S2 Torque the nuts to 60 95 N m 44 70 Ib ft NOTE CHECK THE REAR SUPPORT OF THE AIR COMPRESSOR BEFORE REINSTALLING IF THE BRACKET THAT ATTACHES TO THE COMPRESSOR FIGURE 6 ITEM 1 HAS ONLY ONE 1 MOUNTING POINT WHERE IT ATTACHES TO THE COMPRESSOR IT NEEDS TO BE CHANGED TO THE TWO POINT SYSTEM FIGURE 6 THE PARTS NEEDED FOR THE TWO POINT SYSTEM ARE F3HZ 2902 B AND F4HZ 2W896 A BOTH BRACKETS
94. 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 ta 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 clear coat film Removal of OEM clear coat in excess of 0 03 mil may contribute to prernature clear coat failure and is not recommended THE DECONTAMINATION PROCEDURE DIRECTED IN THIS BULLETIN MUST BE PERFORMED BEFORE ANY BUFFING POLISHING COLOR SANDING OR REFINISHING IS ATTEMPTED TB 4187 A Figure 1 Article 95 6 1 DECONTAMINATION Use Finish Kare Inc products 1119 883 118SC to decontaminate
95. he appropriate Service Manual for replacement procedures OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS INFORMATION ONLY OASIS CODES 505200 506000 95 15 Publication Date JULY 31 1995 Article No 95 15 15 Steering Gear Replacement Of Bendix Steering Gear With Mew Ross Steering Gear MEDIUM HEAVY TRUCK 1986 93 CARGO SERIES 1988 93 F amp B SERIES This TSB is being republished in its entirety to correct part number usage for the pitman arm in Figure 1 and to arrange text to flow with figures ISSUE Production of the Bendix steering gear has been discontinued Sufficient Service parts are available to support the field with Bendix gears for several years However a customer may want the option to replace the Bendix steering gear with the current production Ross steering gear ACTION As required replace the Bendix steering gear with a Ross steering gear Refer to the following procedure and its attachments for part requirements and service details REPLACEMENT OF C500N STEERING GEAR WITH ROSS TAS65 STEERING GEARS APPLICATION F SERIES WITH 10000 12000 LB ROSS TAS65 FRONT AXLE PROCEDURE Bendix Gear Removal 1 Thoroughly clean off all outside dirt especially around fittings CAUTION DO NOT STEAM CLEAN OR HIGH PRESSURE WASH HYDRAULIC STEERING ASSEMBLIES OR FORCE ABUSE CLOSELY FITTED PARTS DAMAGE WILL RESULT 2 Disconnect the power steering pressure and return lines at the gear and drain fluid 3
96. he spring eyes and press in the new shackle bracket bushing 3 Clean the spring eye using the 1 25 brush included in the Rotunda Spring Shackle Repair Kit 139 00100 4 Ream the spring eyes by rotating clockwise with the 1 25 reaming tool included in the Rotunda Spring Shackle Repair Kit 139 00100 The reamer must pass completely through the spring eye to be properly sized NOTE THE REAMER MUST ALWAYS APPROACH THE SUSPENSION CONNECTIONS AS SHOWN IN FIGURE 2 TO PREVENT DAMAGING THE REAMER REAMER pp REAMER DIRECTION DIRECTION REAMER REAMER VEHICUE DIRECTION DIRECTION TB 4269 A Figure 2 Article 95 12 11 5 Press the new bushings F2HZ 5348 A in with C clamps and non expanding arbor D94T 3110 B 6 Clean the shackle and the front spring hanger pin bores by using the 1 00 diameter wire brush included in the Rotunda Spring Shackle Repair Kit 139 00100 Remove all grease from the shackle bracket area that contacts the spring 7 Using the spot face tool and T wrench included in the Rotunda Spring Shackle Repair Kit 139 00100 spot face the shackle and shackle bracket as required to remove any raised or grooved material This will normally be on the thrust side of the bracket which is the location where the steel thrust washers will be placed during assembly Clean the cutting edges of the spot face tool frequently during use with the brush included for cutting performance and bit life
97. he thermostat housing and torque to specification 7 Refill coolant per instructions in the 1995 L Series Service Manual Section 03 03 OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 402000 95 25 Publication Date DECEMBER 18 1995 Vibration Driveline Vehicles With Tandem Axles And Hendrickson Air Suspension Article No 95 25 16 MEDIUM HEAVY TRUCK 1993 95 L SERIES ISSUE Driveline vibration may occur on some vehicles This may be caused by forward tandem axle input joint angles ACTION Refer to the following Service Procedure for diagnosis and details SERVICE PROCEDURE 1 Check to assure that the air suspension ride height is set at 10 8 cm 4 25 at the rear tandem and that the spring seat angles are 6 degrees at the forward tandem and 13 degrees at the rear tandem seat angles are stamped in the front of the axle seat tab on the bottom Verify vibration occurs in the higher gears at or near peak engine torque and that frame pitch measured between the rear axles is less than 45 minutes 3 4 degree Most vehicles with this concern have a main driveline with two 2 shafts the tandem axle also has an inter axle shaft The coupling shaft connects to the U joint at the rear of the transmission and the driveshaft connects to the U joint at the front of the forward tandem axle For vehicles with a two shaft
98. hood i e headlamps marker lamps etc 3 Install the new hood as outlined in the Service Manual 4 Prime and paint the new hood appropriately OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 111000 95 19 Publication Date SEPTEMBER 25 1995 Article No Wiring Hood Wiring Harness Availability Of Hood Wiring Harness Clip 95 19 17 MEDIUM HEAVY TRUCK 1981 91 L SERIES ISSUE An incorrect part supersession occurred causing some customer dissatisfaction The original part DOHZ 14A099 C was superseded with F2HZ 14A099 A These parts have a similar function but are not interchangeable ACTION The original part DOHZ 14A099 C is available for service and should be used when service to the hood wiring harness clip is required OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS INFORMATION ONLY OASIS CODES 203000 Bulletin Contents TSB Article 95 19 18 has been superseded by Article 96 2 9 95 20 Publication Date OCTOBER 9 1995 Hard Starting Or No Starting Extended Engine Shutdown Period FD1060 And Article No FD1460 Diesel Engines Diesel Fuel Draining Back To Fuel Tank 95 20 10 MEDIUM HEAVY TRUCK 1993 95 CARGO SERIES F amp B SERIES L SERIES ISSUE Hard starting or a no start concern may occur on some vehicles This may be due to diesel fuel draining out of the fuel injecti
99. ible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 499000 614000 614500 614600 95 17 Publication Date AUGUST 28 1995 Generator Motorcraft 95 Amp Front Bearing Concern FD1060 1460 Engines Article No Vehicles Built Before 7 3 95 95 17 13 MEDIUM HEAVY TRUCK 1992 95 CARGO SERIES F amp B SERIES L SERIES ISSUE The front generator bearing may have early wear out This is due to the force of the main drive belt load ACTION Verify concern and install a revised Motorcraft 95 Amp Generator F5PZ 10346 GA The revised generator has a double wide front bearing which improves the handling of the force produced from the main drive belt load Refer to the following Service Procedure for details SERVICE PROCEDURE 1 Verify the vehicle is the correct model and year and equipped with a Motorcraft 95 Amp Generator 2 Remove the generator as outlined in the appropriate Service Manual Section 14 024 3 Remove the regulator from the existing generator and install in the revised Motorcraft 95 Amp Generator F5PZ 10346 GA 4 Install new pulley F5TZ 10344 AA on the new Motorcraft 95 Amp Generator F5PZ 10346 GA NOTE DO NOT USE OLD PULLEY ON NEW GENERATOR Install the new Motorcraft 95 Amp Generator F5PZ 10346 GA as outlined in the appropriate Service Manual Section 14 02A OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LAB
100. icle No Steering Tilt And Telescoping Column Kit Availability To Remove Free Play 95 13 8 MEDIUM HEAVY TRUCK 1991 95 L SERIES ISSUE The tilt and telescoping steering column may have free play ACTION To improve this condition a kit has been made available for service which contains an Instruction Sheet and plug OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OASIS CODES 303000 95 13 Publication Date JULY 3 1995 Air Conditioning A C Drive Belt Comes Off Vehicles With Dealer Installed A C And 7 8L Ford New Holland FNH Engine Article No Air Conditioning Lack Of Cooling A C Drive Belt Comes Off Vehicles With Dealer 95 13 9 Installed A C And 7 8L Ford New Holland FNH Engine MEDIUM HEAVY TRUCK 1986 93 CARGO SERIES This TSB is being republished in its entirety to correct the vehicles affected and the model years ISSUE The A C belt may roll off the pulley on some vehicles equipped with dealer installed A C and 7 8L FNH engine This may be due to instability of the idler bracket assembly ACTION Replace the single pulley idler with a new dual pulley idler The dual pulley idler should improve the stability of the long A C drive belt Refer to the following Service Procedure for details SERVICE PROCEDURE 1 Remove the A C drive belt 2 Verify the harmonic balancer pulley has no more than 0 020 runout using a dial in
101. in slowly apply the brake If the lamp goes out reconnect the supply line and go to SECTION III Step 3 SECTION III DIFFERENTIAL VALVE FUNCTIONAL CHECK After Replacement of Valve 1 Again simulate unequal pressure by disconnecting the secondary delivery line on the foot valve Figure 2 Item 1 With ignition on apply the brakes This should cause the piston to shuttle over and allow contact between the piston and switch This contact should cause the lamp to illuminate Illumination of lamp indicates the differential pressure valve system is functioning properly Reconnect the red delivery line Figure 2 Item 1 and loosen the green primary delivery line Figure 2 Item 2 Very slowly apply the brake until the lamp goes out This action forces the piston to shuttle in the opposite direction centering it in the valve body If too much pressure is applied the piston will shuttle too far and the lamp will remain on The procedure to re center the piston will have to be reversed Reconnect green line Figure 2 Item 2 and tighten Last check is with the ignition in the ACC or ON position the brake warning lamp should be off In the start position the warning lamp should be on for approximately 1 2 second With the ignition switch in the ON position step on the brake pedal The warning lamp should remain off If the warning lamp comes on again the brakes may be out of adjustment or a leak exists that was not identified in SECTION I O
102. ing Plastic Air Cleaner Covers 95 7 24 MEDIUM HEAVY TRUCK 1992 95 CARGO SERIES F amp B SERIES L SERIES ISSUE A new service kit for retaining the Diesel Engine plastic Air Cleaner Assembly Covers has been released for service ACTION If it becomes necessary to replace the retaining hardware of a plastic air cleaner assembly use the new Air Cleaner Cover Hold down Kit F4HZ 9C629 A The air cleaner cover hold down kit includes the following e 1 one Thumb Screw e 1 Fastener Piece 1 one Bottom Fastener Piece 1 one Instruction Sheet OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS INFORMATION ONLY OASIS CODES 404000 499000 95 8 Publication Date APRIL 24 1995 Wiper Motor Replacement Upgraded Service Kits Article No Windshield Wiper Motor Upgraded Service Repair Kits 95 8 2 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 This TSB is being republished in its entirety to include F 150 350 Series Bronco F Super Duty and F B Series revise application chart and to include production dates for L Series vehicles IS
103. ing out of the clutch in less than 3 seconds on engagement Lack of air pressure to fully engage the clutch may be due to e A leaking control valve _ Leaking air line s the clutch needs 80 psi to fully disengage Frequent clutch cycling may be due to e Amalfunctioning pressure override switch e Amalfunctioning control valve e Chattering A C high pressure override switch if engaging the clutch frequently at high engine rpm FAN CLUTCH CONTROL SYSTEM DIAGNOSTIC PROCEDURE Problem 1 Fan won t engage when manual override is turned on 2 Fan won t cycle on when air conditioning test is performed 3 Overtemp warming activates before fan engages 4 Engine appears to overheat Fan won t engage when engine coolant temperature gauge is above 91 96 C 195 205 F or overtemp warning activates before fan engages 5 Fan engages at low engine temperatures while vehicle is moving 6 Fan won t run under any condition Manual override switch air solenoid valve or related plumbing or wiring is faulty Outside air temperature is too low thare is a low refrigerant charge or refrigerant pressure switch is faulty a Airsolenoid valve may be plumbed incorrectly b Overtemp waming switch faulty warning light activates prematurely Overtemp warning switch is too far away from the fan temperature switch Temperature gauge is faulty reads high Fan temperature switch is faulty
104. ing surface and an engine noise shield mounting bolt causing the fan clutch pulley to not be parallel to the front of the engine ACTION Replace the main drive belt and remove a bolt which is causing the interference between the fan hub mounting surface and the engine noise shield Refer to the following Service Procedure for details SERVICE PROCEDURE 1 Loosen the generator mounting fasteners and loosen the adjusting nuts enough to remove the V belts from the generator Refer to the Service Manual Section 14 02C 2 Remove the fan clutch assembly Refer to Service Manual Section 03C 05 Remove and discard the 14 rib polygroove drive belt 3 Locate the engine noise shield mounting bolt which is causing the interference Refer to Figure 1 Remove and discard the bolt REMOVE BOLT TO INSTALL FAN CLUTCH LLS LTLS EXTRA COOLING REMOVE BOLT TO INSTALL FAN CLUTCH LLS LTLS STANDARD COOLING 4 FRONT OF VEHICLE REMOVE BOLT TO INSTALL FAN CLUTCH L SERIES INCLUDING LL AND LTL 4198 Figure 1 Article 95 9 14 4 Replace the main drive belt Refer to the Application Chart for the correct belt Reinstall the fan clutch and install the mounting bolts finger tight Adjust the clutch to obtain 1245 1557 Newtons N 280 350 Pounds Force Ib on the main drive belt Torque the mounting bolts to 102 142 N m 75 105 Ib ft 5 Reinstall the generator drive belts adjust the generator to achieve 400 4
105. ion engines jet engines body shops etc These particles mechanically magnetically bond to vehicles painted surfaces Moisture and temperature combine with the particles to create a chemical reaction The reaction causes the particles to corrode and enter into the physical paint film ACTION To remove these particles contaminants USE ONLY the following procedure The procedure must be performed before any buffing polishing color sanding or refinishing is attempted The materials in this procedure are alkaline acidic and neutral They must be used in the specified order CAUTION ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR AND MAY RESULT IN POSSIBLE DAMAGE TO THE PAINTED SURFACES AND TRIM WARNING THE TECHNICIAN MUST WEAR PROTECTIVE CLOTHING AND EYE PROTECTION TO PREVENT SKIN IRRITATION CAUTION THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM FLEXIBLE PAINTED SURFACES OR OTHER PAINTED SURFACES FOLLOW DIRECTIONS EXACTLY AND RINSE THOROUGHLY AFTER EACH STEP NOTE THIS DECONTAMINATION PROCEDURE IS DESIGNED TO REMOVE SURFACE CONTAMINANTS FROM THE PAINT ON VEHICLES THAT HAVE BEEN CONTAMINATED UP TO 120 DAYS VEHICLES WHICH HAVE EXPERIENCED THE CONDITION LONGER THAN THIS PERIOD MAY REQUIRE AN ADDITIONAL TREATMENT TO REMOVE FERROUS METAL CONTAMINANTS IDENTIFICATION For ease of identifying the Radio Shack Model 63 851 30X lighted magnifier is recommended 1 Ferrous
106. ior surfaces to prevent damage c Apply one 1 coat of self etching primer over all exposed bare metal areas Follow manufacturer label instruction d Follow with one 1 coat of primer surfacer Follow manufacturer label instruction e Apply topcoat per manufacturer label instruction 3 Remove the components of the kit and identify the top bottom left and right parts On the left and right parts locate the UP arrow which indicates the top of part Refer to Figure 1 WINDSHIELD WEATHERSTRIP WINDSHIELD MOULDING WINDSHIELD OUTSIDE COVER WINDOW OUTSIDE MOULDING JOINT URETHANE KIT m ROM VIEW VIEW IN CIRCLE D NOTE DRAIN SLOTS MUST BE CLEAN VIEW B SECTION E ASSEMBLED 4051 Figure 1 Article 95 3 26 4 Install the right and left urethane components on the flange of the windshield opening ensuring the arrows are pointing up Refer to Figure 1 5 Install the top and bottom urethane components across the top and bottom flange of the windshield opening Refer to Figure 1 6 Replace weatherstrip and windshield OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 102000 106000 95 3 Publication Date FEBRUARY 13 1995 Steering Revised Camber Specification Vehicles Equipped With 10K 12K 13 2K Article No And 14 6K Front Axles 95 3 27 MEDIUM HEAVY TRUCK
107. isconnect the drag link from the pitman arm 4 Remove the pitman arm pitch bolt and nut Remove the pitman arm from the sector shaft using Pitman Arm Puller T64P 3590 F 5 Remove intermediate shaft U joint nut and bolt and disconnect it from the steering gear input shaft 6 Disconnect steering gear mounting hardware and remove the gear from the truck s side rail NOTE THE 5 8 MOUNTING BOLTS MUST BE REPLACED BY 3 4 SIZE BOLTS TO REMOVE THE TWO 2 FORWARD 5 8 BOLTS CUT THE BOLTS IN HALF THE SIDE RAIL HOLES MUST THEN BE ENLARGED TO TAKE THE 3 4 BOLTS RECOMMENDED HOLE SIZE IS 0 812 0 786 DIAMETER 7 hydraulic lines and remove power steering pump NOTE REMOVE THE DRIVE GEAR FROM THE PUMP ON DIESEL ENGINES AND REMOVE THE PULLEY AND RESERVOIR FROM THE PUMPS ON GAS ENGINES AND SAVE THESE PARTS WILL BE REUSED ON THE REPLACEMENT PUMPS NOTE REFER TO FIGURE 2 FOR PART USAGE INFORMATION STEERING GEAR CONVERSION CHART F AND B SEHIES MODEL YEARS 1988 THROUGH 1993 6 7000 LB FRONT AXLES BENDIX C300N TO ROSS TAS40 8 9000 LB FRONT AXLES BENDIX C300N TO ROSS TAS55 E8HT 3N503 AD C300N F3HZ 3504 A 540 FiHT 3N503 HA 300 OR F2HT 3N503 BA 300 F4HZ 3504 A TAS55 MOUNTING HARDWARE NEW 59747 52 3 4 x 10 x 3 5 GRADE amp LOWER REAR BOSS NEW 58749 52 3 4 x 10 x 4 0 GRADE 8 FORWARD 2 BOSSES NEW 34992 52 3 4 x 10 GRADE 8 NUT HEX HEAD TORQUE PREVAILING NEW 44882 52 3 4
108. km THEREAFTER FOLLOW THE MAINTENANCE SCHEDULE FOR CORRECT RETORQUE INTERVALS OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS INFORMATION ONLY OASIS CODES 304000 Bulletin Contents TSB Article 95 4 6 has been superseded by Article 95 8 2 95 4 Publication Date FEBRUARY 27 1995 Lack Of Power Excessive Free Play At Throttle Linkage Frequent Throttle Linkage Adjustments FNH 6 6L And 7 8L Engines Article No Throttle Linkage Excessive Free Play Lack Of Power FNH 6 6L And 7 8L Engines 95 41 10 Frequent Throttle Linkage Adjustments MEDIUM HEAVY TRUCK 1986 93 F amp B SERIES L SERIES This TSB is being republished in its entirety to include the correct Dealer Coding and Condition Code ISSUE The Ford New Holland engine may exhibit the need for frequent throttle linkage adjustments because the throttle linkage accelerator pedal has excessive free play or the engine lacks power This may be caused by the governor lever which may wear and prevent the fuel injection pump from reaching Wide Open Throttle WOT Adjusting the throttle linkage can compensate for this wear but eventually the wear in the governor lever will exceed the adjustment capability of the throttle linkage ACTION Inspect the condition and operation of the Governor Lever Assembly If the governor lever is excessively loose or can be rocked side to side it should be replaced PART FEATURES e Smaller throttle rod attachi
109. l not within the 0 001 0 005 0 025 0 127mm range disassemble and inspect the components If parts are found to be defective replace the defective parts reassemble and repeat wheel bearing adjustment procedure Verify end play with a dial indicator WHEEL END LUBRICATION NOTE BEFORE OPERATING THE AXLE THE WHEEL HUB CAVITIES AND BEARINGS MUST BE LUBRICATED TO PREVENT FAILURE When wheel ends are serviced follow Eaton s wheel end lubricating procedure before operating the axle Eaton axles may be equipped with either of the following two 2 wheel end designs e Wheel ends with an oil fill hole Figure 11 WHEEL END OIL FILL HOLE PROPER LUBRICANT LEVEL WHEEL END WITH OIL FILL HOLE WHEEL END WITHOUT OIL FILL HOLE PROPER LUBRICANT LEVEL 6 LUBRICANT FLOW FROM SUMP TB 4314 A Figure 11 Article 95 15 16 Wheel ends without an oil fill hole Figure 11 WHEEL ENDS WITH AN OIL FILL HOLE 1 Rotate the wheel end hub until the oil fill hole is up 2 Remove the oil fill plug 3 Pour 1 2 pint of axle sump lubricant into each hub through the wheel end fill hole 4 Install oil fill plug and tighten to the specified torque WHEEL ENDS WITHOUT AN OIL FILL HOLE 1 With the axle level and wheels assembled add lubricant through filler hole located in axle housing cover until fluid is level with the bottom of the filler hole 2 Raise the left side of the axle 6 152mm or more
110. le Shorten the throttle rod until approximately 1 16 of break over is achieved at the throttle lever Tighten the jam nuts Ensure lever has break over when the accelerator pedal is at wide open throttle Final Inspection 13 The final inspection steps are as follows a Once the new parts have been installed and attaching nuts torqued properly check the operation of the accelerator pedal and linkage to ensure it works easily and returns properly The pedal must return completely from wide open throttle without any drag or binding No surrounding engine compartment components hoses wiring etc may contact any moving part of the accelerator controls If the vehicle is equipped with a hand throttle check the throttle handle for flushness with the dash panel when engine is at idle Adjust if required NOTE THE NEW GOVERNOR LEVER DOES NOT HAVE AN INDEXING FEATURE THEREFORE FOR ANY FUTURE FUEL INJECTION PUMP OR LINKAGE REPAIR THAT REQUIRES REMOVAL OR REPLACEMENT OF THE GOVERNOR LEVER IT WILL BE NECESSARY TO NOTE AND OR MARK THE LOCATION OF THE LEVER SO THAT IT CAN BE REINSTALLED IN THE CORRECT POSITION F B SERIES 1 2 10 11 12 13 Remove the throttle return spring from the governor lever Disconnect the throttle rod from both the governor lever and the accelerator pedal lever On this application the rod must be replaced NOTE BEFORE REMOVING THE OLD GOVERNOR LEVER USE A PERMANENT MARKIN
111. lt pulley Figure 1 FD 1060 ENGINE DAMPERS RUBBEH TYPE DAMPER OLD VISCOUS DAMPER NEW VISCOUS DAMPER Figure 1 Article 95 10 18 POWER TAKE OFF PTO USAGE Both the rubber and viscous dampers can be used with a crankshaft mounted PTO adapter Refer to the Application Chart for the correct part number and application VISCOUS DAMPER RETROFIT Use the following parts to retrofit a viscous damper in place of a rubber damper e Viscous Damper F3HZ 6312 G e Adapter F3HZ 6A329 A e _ Drive Belt Pulley F3HZ 6312 A e Bolt Kit longer capscrews Cummins part number 3924584 or Ford part number 3924584 CF1 hex flange head capscrews Refer to Section 03A 01 of the appropriate Powertrain Drivetrain Service Manual for the damper installation procedures and attaching bolt torque specifications OTHER APPLICABLE ARTICLES 94 8 24 WARRANTY STATUS INFORMATION ONLY OASIS CODES 490000 499000 95 11 Publication Date JUNE 5 1995 Transmission Rockwell RMX9 Overdrive Transmissions Transmission Article No Countershaft End Clearance May Not Be Within Specification Vehicles Built From 95 11 17 411190 Through 1 31 83 Serial Numbers LB9000240 Through LB93001999 MEDIUM HEAVY TRUCK 1990 94 L SERIES This TSB article is being republished in its entirety to revise the affected serial numbers and vehicles ISSUE The transmission countershaft bearing end clearance may not be within specification on some
112. main driveline verify coupling shaft U joint yokes are phased at 90 degrees crossed when viewed from one end and that driveshaft U joint yokes are phased at 0 degrees parallel when viewed from one end If the vibration is not eliminated by correcting the yoke phasing the center bearing support height may need further adjustment to bring the center joint angle into the range shown in the following Recommended Support Mounting Chart This angle is found by adding the slope of the coupling shaft down toward the rear to the slope of the driveshaft up toward the rear If the slopes are in the same direction subtract the smaller slope from the larger slope to determine the joint angle Check the pinion angle of the forward rear axle If the pinion angle is greater than 6 degrees in relation to the ground proceed with the following If the pinion angle is less than 6 degrees in relation to the ground do not proceed with the following noise vibration and harshness will be increased if performed If Steps 1 5 have been performed and the pinion angle is greater than 6 degrees Step 6 remove the forward tandem spring seats and replace them with new 4 degree seats and 1 spacers to reduce the forward tandem axle pinion slope and input joint angle Remove the forward rear axle spring seats and discard refer to the appropriate year L Series Service Manual Section 04 02E Install the 4 degree axle seats and spacers F6HZ 5793 RA Figure
113. n on some and no bracket separation on others ACTION Install a tubular support bracket which attaches to the engine cylinder head and hydraulic reservoir brackets Refer to the following Service Procedure for details SERVICE PROCEDURE 1 Remove the Hydromax Brake Reservoir Item 1 Figures 1 and 2 Discard the reservoir four 4 nuts and two 2 of the bolts Install a new Hydromax Brake Reservoir F5HZ 2N148 A F B Series and F3HZ 2N148 A LN Series using two 2 of the existing bolts on the right side with two 2 new torque prevailing 5 16 18 Grade 5 nuts 33770 S2 Item 5 Figures 1 and 2 Torque nuts from 16 23 N m 12 17 Ib ft VIEW FOR F B SERIES Figure 1 Article 95 10 13 Figure 2 Article 95 10 13 2 For F B Series remove the bolt Item 4 Figure 1 from the engine cylinder head charge air tubing casting which retains the 9A627 air cleaner bracket Discard bolt LN Series vehicles do not have a bolt in this location 3 Install the Tubular Support Bracket Item 3 Figures 1 and 2 F5HZ 2K017 BB F B Series and F5HZ 2K017 AB LN Series to the reservoir and reservoir mounting bracket Use two 2 new 5 16x18x1 00 Grade 5 flanged bolts 376256 S Item 2 Figures 1 and 2 and two 2 new torque prevailing 5 16x18 Grade 5 flanged nuts 33770 S2 Item 5 Figures 1 and 2 Torque nuts from 16 23 N m 12 17 Ib ft 4 For F B Series and LN Series Install a 1
114. nce this condition is corrected the valve will have to be re centered After this procedure is done and valve is functioning properly the General Inspection Procedures should be done to check the brake system functionality refer to Cargo Service Manual Section 12 Brakes Air Hydraulic Brakes OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS INFORMATION ONLY OASIS CODES 301000 95 10 Publication Date MAY 22 1995 Air Conditioning Availability Of Conversion Kits To Convert Systems Using R 12 To Article No R 134A 95 10 16 MEDIUM HEAVY TRUCK 1985 91 C SERIES CL 9000 1985 94 F amp B SERIES L SERIES 1986 94 CARGO SERIES ISSUE Conversion kits are available to convert systems using R 12 refrigerant to R 134a refrigerant ACTION If it becomes necessary to convert A C systems using R 12 refrigerant to R 134a refrigerant refer to the following for details RPO A C R 12 TO R 134a CONVERSION It is important to note the following when converting R 12 systems to R 134a systems This process will permanently convert a factory installed R 12 A C system to an R 134a system Once converted the system cannot be converted back to an R 12 system It is recommended that all R 12 systems be repaired using R 12 whenever possible e f R 12 is not available the system must be converted to an R 134a system e 12 substitutes are NOT recommended or approved Conversion to R 134a is the only acceptable method
115. necessary d Replace fan temperature switch e Replace pressure switch a Normal conditian in hot weather b Service A C system Check A C pressure and condenser l out of calibration replace pressure switch a Check wiring Fix where necessary b If other systam components and connections check out OK Replace pressure switch if erratic fan operation is associated with air conditioning at idle OR Replace fan temperature switch if erratic operation occurs primarily when the engine is hot TB 3276 B Figure 3 Article 95 25 14 FAN CLUTCH CONTROL SYSTEM DIAGNOSTIC PROCEDURE Problem Possible Cause Fan cycles frequently when engine is hot Fan cycles frequently when vehicle is stationary with A C on Fan tums on whenever ignition is on turns off when engine gets hot Control system fuses blown The fan should remain engaged long enough to reduce tempera ture 3 5 5 7 10 F The fan temperature switch is defective if the fan disengages after only 1 5 2 3 4 F reduction Up to 4 cycles per minute is normal condition for conventional control systems Turn aff air conditioning system and cycling should stop Air solenoid valve plumbed backward Replace fan temperature switch To reduce cycling by up to 90 install an Index K7 fan control system Check solenoid installation instructions Plumb correctly
116. ng and holding in the colored release buttons while pulling out the tubing NOTE EACH PORT HAS A METAL INSERT OR SLEEVE WHICH ENGAGES THE TUBING INSIDE DIAMETER SHOULD THIS INSERT PULL OUT OF THE PORT WITH THE TUBING MAKE SURE IT IS RE ENGAGED INTO THE REPLACEMENT TUBING UPON REASSEMBLY Remove the fastener securing the aluminum cover plate Remove the two 2 screws securing the electrical mode switch to the bracket Remove the two 2 Phillips head screws securing the spool valve assembly to the bracket Lift the spool body gently from the mounting recess by sliding the spool to the lower end of the spool guide track Take care not to damage the spool guide fingers CAUTION DO NOT PULL THE SPOOL OUT OF THE SPOOL BODY IF THE SPOOL IS REMOVED IT COULD BECOME CONTAMINATED AND RESULT IN A CONTROL ASSEMBLY FAILURE INSTALLATION 1 Apply a small amount of grease Lubriplate 30 to the spool guide track 2 Gently position the spool slider into the guide track and locate the spool body into its recess 3 Reinstall the spool valve assembly and secure with the two 2 Phillips head screws 4 Align the lever slot with the spool slide hole Position the mode switch so the switch post passes through the lever slot and slide holes and install the mode switch fasteners 5 Reinstall the aluminum cover plate and secure with fasteners 6 Reconnect the tube harness to the appropriate color coded ports Each tube end has a positive i
117. ng bolt hole on L Series this will require a smaller throttle ball stud on F B Series a new throttle rod assembly is used It does not have an indexing feature as the previous lever did the new lever be installed in any position on the injection pump shaft Around spacer with a flat spot in slot gap of the governor lever this spacer must be rotated so the flat spot is aligned with the pump shaft before the new lever can be installed Figure 1 OLD LEVER LEVER SLOT GAP BEFORE REMOVING THE OLD LEVER MARK THE INJECTION PUMP SHAFT WHERE THE SLOT GAP POSI TIONED THIS MARK WILL BE USEB TO PROPERLY POSITION THE NEW LEVER Figure 1 Article 95 4 10 CAUTION THE OLD STYLE GOVERNOR LEVER IS DESIGNED SO IT CAN BE INSTALLED ON THE PUMP SHAFT IN ONLY ONE 1 POSITION THE NEW LEVER DOES NOT HAVE THIS FEATURE AND IT IS VERY IMPORTANT THAT THE LEVER IS POSITIONED CORRECTLY TO ENSURE PROPER ENGINE OPERATION PLEASE READ THIS ENTIRE PROCEDURE BEFORE ATTEMPTING ANY REPAIRS THEN FOLLOW THIS PROCEDURE CAREFULLY REPAIR PROCEDURES L SERIES 1 Remove the throttle spring from the governor lever 2 Disconnect the throttle ball stud from the governor lever 3 Attach the new ball stud to the throttle rod and screw it on so that it is in the same position as the old one was NOTE BEFORE REMOVING THE OLD GOVERNOR LEVER USE A PERMANENT MARKING PAINT TO MARK THE LOCATION OF THE OLD GOVERNOR LEVER ON THE PUMP SHAF
118. nt Axle Shudder Vibration When Brakes Are Applied 95 16 20 Vehicles Equipped With 14 600 16 000 And 18 000 Lb Front Axle Assemblies Equipped With Rockwell 16 5 X 6 Inch Brake Assemblies MEDIUM HEAVY TRUCK 1990 95 L SERIES ISSUE The front end may shudder vibrate on some vehicles equipped with the above mentioned axles when the brakes are applied This condition will be evident at low speeds and low deceleration rates when the front end is lightly loaded with respect to the gross axle weight rating ACTION Replace the front brake lining material with a revised material which has different friction properties to properly match a lightly loaded front end with the torque of the front brakes Using these linings does not reduce the GAWR of the applicable axle and is offered as a DSO option Refer to the following for service details SERVICE PROCEDURE 1 Remove the front tires hubs brake drums and shoes as outlined in the L Series Service Manual Sections 04 01 and 06 08D 2 Reine the brake shoes using the applicable brake lining kit 3 Check the condition of the brake return springs and rollers replace if necessary 4 Reinstall the brake shoes return springs rollers and brake drums as outlined in the L Series Service Manual Section 06 08D 5 Check the condition of the wheel bearings replace if necessary Install a new wheel seal and wear ring if applicable into the hub Install the hub and adjust the bearings as ou
119. of updating an R 12 system PROCEDURE An RPO A C system conversion requires two 2 parts e Order an R 12 to R 134a conversion kit from the following Application Chart One 1 kit will be needed for each vehicle converted A complete instruction sheet is included with each conversion kit e Anew accumulator or receiver drier must also be ordered Replace the current accumulator with a new accumulator of the same part number e L Series vehicles built prior to the 1991 1 2 model year used a receiver drier instead of an accumulator Replace the current receiver drier with a new receiver drier chosen from the following chart NOTE R 134a REFRIGERANT AND CHARGE EQUIPMENT WILL BE REQUIRED For L Series vehicles built prior to the 1991 1 2 model year December 1991 replace the receiver drier with an R 134a compatible receiver drier see chart below All other vehicles have R 134a compatible components SLEEPER HEATER A C UNITS e X Sleeper evaporator cores are located beneath the bunk the luggage compartment area All R 12 evaporator cores are Box shaped units and all R 134a evaporator cores are Wedge shaped units e 12 evaporators can be made R 134a compatible by changing the Thermal Expansion Valve TXV IN ADDITION TO ALL CHANGES RECOMMENDED TO THE BASE RPO SYSTEM e The old R 12 Red Dot part number RD 4157 0 should be replaced with a 1 1 2 ton R 134a TXV part number RD 5 7125 0 available directly from R
120. ome on TYPICAL BRAKE SCHEMATIC CARGO 6000 7000 AIR HYDRAULIC SYSTEM 9t SECONDARY emen PRIMARY 2 SUPPLY TO MEN pip E6 VALVE eg art LJ BINGLE CHECK VALVE Ea PRIMARY Mil 1 SN BRAKE Free E ITEM 2j L q i Ta ml mew LEN PT DRAINCOCK P 1 LI O s e 1 1 ig H E TA NYLON 1 Eli BAAKE er i SHIRA 1 COMPRESSOR hie STEEL METUS H 1 STEEL EJE Men 1 1 1 STEEL bmc je reme oe ee WANN al HECK a wise pend EBHZ 2K483 A SINGLE CHECK 2 1 1 1 Parera 1 x TURAE H 1 1 E HATAN H EHE ERU BEINE 14 1 y 1 STEEL PANA 1 eee Nom ia LS DEWINCDCK H I SN Rd 20522 1 _ _ _ ur 44 12 NYLDM EM H IO NYLON 181 b We ee nn eee a m m m ASSEMBLY SPPN PRIMARY AIR SYSTEM GREEN RUBBER HOSES Lam SECONDARY AIR SYSTEM RED PARKING AIR SYSTEM PARKING SYSTEM ORANGE PRIMARY SYSTEM ETT FRONT HYDRAULIC SYSTEM RED SECONDARY SYSTEM REAR HYDRAULIC SYSTEM GREEN TB 4215 A Figure 2 Article 95 10 14 4 Ifthe brake warning lamp does not illuminate when pressure is not equal in both brake systems
121. on system back into the fuel tank This condition causes the injection system to lose its prime which leads to longer starter engagement times for engine cranking or a no start concern This is most noticeable after an extended engine shutdown period ACTION Install a Diesel Fuel Check Valve F5HZ 9285 AA on the fuel return line at the rear of the engine This valve will allow fuel to return during normal engine operation Refer to the following Service Procedure for details SERVICE PROCEDURE 1 If equipped remove the engine cover from inside the cab Locate the fuel return line Figure 1 For vehicles not equipped with a removable engine cover the fuel return line must be accessed from under the vehicle FUEL RETURN LINE FRONT OF VEHICLE FD1060 ENGINES EQUIPPED WITH INLINE INJECTION PLIMP FD1060 ENGINES EQUIPPED WITH 160 HP AND ROTARY INJECTION PUMP FUEL RETURN LINE SAY 9 22 22 gt qu P AENA el LS pet ABIT 2 FD1460 ENGINES TB 4334 A Figure 1 Article 95 20 10 2 For the FD1060 or FD1460 engine remove the fuel tank return line from the engine fuel return line Use a suitable container to collect residual fuel which may be contained in the line 3 Install the Fuel Check Valve F5HZ 9285 AA between the engine fuel return line and the fuel tank return line Tighten both fittings 4 Start engine and check for leaks If equipped reinstall the engine cove
122. on the brass fitting which could block the current flow from the brass through the coolant to the tip A vehicle with this condition will typically show a low coolant level code from 25 000 50 000 miles 40 200 80 400 km when the coolant is actually at the proper level To correct this concern perform the following 1 Remove enough coolant from the reservoir to remove the low coolant level sensor and remove the sensor from the reservoir 2 With the key in the On position and using Rotunda Digital Volt Ohmmeter 014 00407 or equivalent check the polarity of the low coolant level sensor This system operates on approximately 5 volts DC current Connect the positive probe to the tip and the negative probe to the brass connector A positive reading should appear If a negative voltage is present the polarity is incorrect and needs to be reversed 3 Ifthe polarity is incorrect turn the ignition key to the Off position and change the polarity by removing the wires from the connector shell and reversing their position 4 Remove the sensor and examine the edge of the brass which conducts the current for corrosion build up Figure 1 If corrosion is present remove the corrosion with a small knife and emery cloth taking caution not to cut or abrade the plastic tip insulator LOW COOLANT LEVEL SENSOR HEMOVE CORROSION BUILD UP 4 SEE VIEW VIEW B AREA OF CORROSION BUILD UP TB 4119 A Figure
123. oosely route the new wiring assembly F4HZ 14A411 A from the area of the turn signal switch on the steering column to the area of the circuit panel Figures 1 and 2 RELOCATE THE TURN SIGNAL FLASHER AND ATTACH TO PART OF 14A067 FUSE JUNCTION PANEL A 130747 Gr A 7 1 5 OPEN SURFACE USING THE ORIGINAL SCREWS KL CIRGUIT BREAKER AND FUSES a UN rai 54 El IE A Ae 1 LY CUT EXISTING WIRE AND REMOVE EYELET INSTALL EYELET FROM THE 13C747 WIRING ASSEMBLY IN PLAGE OF EXISTING Figure 1 Article 95 5 30 TRACTOR TRAILER TURN SIGNAL CIRCUIT ISOLATION TAPE REMAINING WIRE END OF 44 CIRCUIT TO MAIN WIRING REMOVE TERMINAL AND GUT THE EXISTING 44 CIRCUIT WIRE BLUE VIEW IN DIRECTION 130747 JUMPER OF ARROW A HARNESS BLUE VIEW IN DIRECTION OF ARROW Y REFERENCE 14401 WIRE ASSEMBLY TB 3588 A CONNECTOR LOCK RED JUMPER HARNESS TO TURN SIGNAL Figure 2 Article 95 5 30 2 Identify the connector to the turn signal switch which contains six 6 circuits a Disconnect the connector and remove Circuit 44 blue pin from the 14401 connector by removing the red locking wedge and releasing the latching tine b Cut off the pin and tape the remaining wire end Figure 2 NOTE IF THE CONNECTORS NEED REPLACING REFER TO THE PARTS LISTINGS FOUND AT THE END OF THIS ARTICLE FOR THE PROPER PARTS 3
124. opriate year L Series Service Manual Section 03C 12 for details OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OASIS CODES 499000 Bulletin Contents TSB Article 95 22 7 has been superseded by Article 95 25 3 95 23 Publication Date NOVEMBER 20 1995 Article No Paint 1996 Color Chart Aftermarket Supplier Cross Reference List 05 23 1 FORD 1996 ASPIRE CONTOUR CROWN VICTORIA ESCORT MUSTANG PROBE TAURUS THUNDERBIRD LINCOLN MERCURY 1996 CONTINENTAL COUGAR GRAND MARQUIS MARK VIII MYSTIQUE SABLE TOWN CAR TRACER LIGHT TRUCK 1996 AEROSTAR BRONCO ECONOLINE EXPLORER F SUPER DUTY F 150 350 SERIES RANGER VILLAGER WINDSTAR MEDIUM HEAVY TRUCK 1996 CARGO SERIES F amp B SERIES L SERIES ISSUE The following 1996 Ford and Lincoln Mercury color charts Figures 1 through 4 provide all of the supplier paint code numbers for the Ford two digit paint codes listed on the Vehicle Certification Label Color Naw 1996 FORD CAR AND LIGHT TRUCK PAINT CODES Martin Senour cma BASF Kt Spies Sherwin Williams R M Glagurit Autocolor Hecker Standox je 5920 Oion white soa co vo 360 62 0 Colonial White Soid co vv se 6346 Vermilion Solid co e 6373 Ebony Solid C C co ua so GacerwieSoit cO 20 go 6414 Desp Jewel Green
125. or mounting bolt Torque bolt to 23 N m 17 Ib ft Torque the discharge line tubing nut to the A C compressor from 20 27 N m 15 20 Ib ft Route the discharge line into the clip points on the cooling module Before tightening install the discharge line into the condenser and reinstall the 19E746 A C lock removed in Step 4 on the spring lock coupling Using a new 5 16 18 Grade 5 hex P T flanged nut 379930 S36 or equivalent on the right rear side of the cooling module re clip the discharge line and torque nut from 16 23 N m 12 17 Ib ft On the left rear side clip the discharge line the bolt and U spring clip may be reused Torque from 16 23 N m 12 17 Ib ft On the left side of the module near the condenser clip the discharge line and use the 1 4 20x0 5 bolt removed earlier Torque bolt from 9 6 13 N m 85 115 Ib in 8 For vehicles equipped with an air operated fan clutch install the pressure sensor connector into the pressure sensor located on the new discharge line assembly the location of the sensor has changed from the old discharge line use electrical tape to secure any excess wiring 9 Evacuate and charge the A C system as outlined in the appropriate Service Manual Section 12 03 OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 208000 208200 Bulletin Contents TSB Article 95 18 12 has been superseded by Article 9
126. orated into these instructions The new procedure allows the springs to remain fastened to the front axle Also the need for the broach D94T 3110 A or equivalent has been eliminated ACTION Install the new thicker hardened steel thrust washers to improve the fit up of the front springs and lubricate the bushings with Ford approved grease The new bushings were added in production during the 1993 model year launch The new washers are a service part only to correct the bushing spring bracket tolerance issue Refer to the following procedure for service details THE ROTUNDA SPRING SHACKLE REPAIR KIT 139 00100 MUST BE USED TO PERFORM THIS TSB ARTICLE THE KIT INCLUDES THE FOLLOWING e 2 25 Diameter Spot Facing Cutter Piloted e T Wrench with 4 Tube e 8 Extension Tube e Bit Cleaning Brush e Hex Driver Tool Case e 1 25 Diameter Reamer e 1 00 Diameter Wire Brush e 1 25 Diameter Wire Brush Three 3 Replacement Carbide Bits One Replacement Set NOTE REFER TO THE 1994 L SERIES SERVICE MANUAL SECTION 04 01A FOR ILLUSTRATIONS AND FASTENER TORQUE VALUES INSPECTION PROCEDURE 12 b Apply the parking brake and chock the rear wheels Raise the front of the vehicle evenly until the front wheels are off the ground Position jack stands under each frame rail and lower the vehicle onto the stands This removes the weight from both sides of the front suspension NOTE PERFORM THE FOLLOWING AT BOTH THE FRO
127. ort leaks Pressure Relief Valve PRV leaks compressor shaft seal leaks hose leaks etc Remember to use polyalkylene glycol PAG oil with R 134a systems and mineral oil with R 12 systems OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS INFORMATION ONLY OASIS CODES 208000 208999 95 5 Publication Date MARCH 13 1995 Article No 95 5 26 Instrument Panel Panel Cover Cracks Near Hand Throttle City Delivery Vehicles MEDIUM HEAVY TRUCK 1987 94 L SERIES ISSUE The instrument panel cover may crack near the hand throttle on L Series with the City Delivery Package This occurs because this area of the panel lacks sufficient support ACTION Install a redesigned instrument cluster support bracket to prevent cracking of the instrument panel cover The new bracket can be retrofitted on all 1987 94 City Delivery units If the cover is already cracked install a new instrument cluster cover assembly which includes the reinforcing bracket Refer to the appropriate model year L Series Service Manual Section 13 01 for removal and installation procedures OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 107000 Bulletin Contents TSB Article 95 5 28 has been superseded by Article 97 6 30 95 5 Publication Date MARCH 13 1995 Air Conditioning Heater Little Or No Air From Defrost Register Vehicles Built From 12 1 01
128. oved in a previous step Install twelve 12 new 9 16 18 Grade 8 torque prevailing nuts 55720 52 and torque to 135 165 lb ft 183 224 N m Install a new wheel seal into the hub and reinstall the hub drum on the axle For Rockwell Axles adjust the wheel bearings as outlined in the appropriate Service Manual Section 04 02B For Eaton Axles refer to the procedures found in this article Install the axle shaft gasket dowels washers and nuts and torque the axle shaft nuts to the specifications listed in Section 04 02B of the appropriate Service Manual Install the brake chambers and slack adjusters and manually adjust the slack adjusters for initial brake adjustment Reinstall the wheels and torque to the proper specifications The following Service Procedures apply to all Eaton drive axle wheel and assemblies and has been taken from Eaton Bulletin AXIB 9405 This bulletin details the following service and assembly procedures Wheel end seal installation e Wheel bearing adjustment for the three piece tang type three piece dowel type and four piece tang dowel type lockwasher wheel nut systems e Wheel end lubrication WARNING NEVER WORK UNDER A VEHICLE SUPPORTED BY ONLY A JACK ALWAYS SUPPORT THE VEHICLE WITH STANDS BLOCK THE WHEELS AND ENSURE VEHICLE WILL NOT ROLL BEFORE RELEASING THE BRAKES WHEEL END SEAL NOTE WHEEL END SEALS CAN BE EASILY DAMAGED DURING HANDLING LEAVE THE SEAL IN THE PACKAGE UNTIL INSTALLATION TO PREVE
129. r OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 602300 603300 95 20 Publication Date OCTOBER 9 1995 Air Conditioning Compressor Rear Support Bracket Cracks Vehicles With Cummins Article No L10 M11 Or N14 Engine 95 20 11 MEDIUM HEAVY TRUCK 1988 95 L SERIES ISSUE The A C compressor rear support bracket may crack on some vehicles ACTION If the original bracket is cracked replace the bracket with a revised design bracket which will reduce the potential for cracking Refer to the 1995 L Series Body and Chassis Service Manual Section 12 034 for removal and installation procedures OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 208999 95 20 Publication Date OCTOBER 9 1995 Article No Gauge Temperature Inaccurate Readings FD1060 Engine 95 20 12 MEDIUM HEAVY TRUCK 1993 95 F amp B SERIES L SERIES ISSUE The engine coolant temperature gauge may read on the cold side of the normal range or may stay below normal even though the engine is at its proper operating temperature on some vehicles This is caused by the coolant temperature sending unit not being positioned in the main stream of coolant flow Instead the sender is located in a pocket of coolant that is outside the normal coolant flow and cannot
130. rm s notch with the notch on the end of the sector shaft Use a chisel to spread the pitman arm and slide it onto the sector shaft 4 nstall arm pitch bolt and nut Torque nut to 407 433 N m 300 320 Ib ft 5 X Attach pitman arm to drag link Torque to 103 142 N m 76 105 lb ft Insert cotter pin 6 Install 45 degree elbow on gear pressure port and align the elbow so that its centerline is parallel to the truck s side rail Attach pressure and return lines to the gear TAKE CARE NOT TO CRIMP THE LINES Refer to Figure 4 for elbow orientation 7 Fillthe reservoir with Motorcraft MERCON Multi Purpose Auto Transmission Fluid XT 2 QDX E4AZ 19582 B or equivalent 8 Tocheck system for leaks remove air from the system and check power assist through range of wheel articulation Start engine rotate wheels from wheel stop to stop DO NOT HOLD THE WHEELS AGAINST THE STOPS FOR LONGER THAN 5 SECONDS If there is a significant reduction in power assist before reaching the stop bolts check stop bolts for proper setting If the bolt setting is correct or the setting has been corrected and stop bolts still are not contacted refer to the Truck Service Manual Steering Diagnosis and Testing Section REPLACEMENT OF C500 STEERING GEAR WITH ROSS TAS65 STEERING GEARS APPLICATION CF SERIES WITH 12000 LB ROSS TAS65 FRONT AXLE PROCEDURE Bendix Gear Removal 1 Thoroughly clean off all outside dirt especially around fittings CAUTION D
131. rn with the brake chambers and the asphalt spreader or other aftermarket equipment ACTION If interference is a concern and the vehicle was not DSO equipped with the asphalt spreader option re index the rear brake chambers Refer to the following Service Procedure for details SERVICE PROCEDURE 1 Chockthe front wheels to prevent unintended movement and remove the rear wheels axle shafts hubs and brake drums Refer to the appropriate Service Manual Sections 05 02A and 04 04 for details 2 Remove the foundation brakes of the tandem rear axle including the brake spider camshaft bracket etc Refer to the appropriate Service Manual Section 06 08D for details Check the condition of the slack adjusters and brake chambers Retain for re use if they are in an acceptable condition 3 Referto the Application Chart listed in this article to install the correct brake assembly and refer to the correct Figure for brake assembly indexing FRONT OF VEHICLE TB 4265 A Figure 1 Article 95 15 16 AXLE HOUSING BRAKE ASSEMBLY FRONT OF VEHICLE TB 4266 A Figure 2 Article 95 15 16 FRONT OF VEHICLE TB 4267 Figure 3 Article 95 15 16 FRONT OF VEHICLE TB 4263 Figure 4 Article 95 15 16 4 Install the correct brake assembly using the correct Figure Install the twelve 12 9 16 18x1 88 Grade 8 bolts and twenty four 24 flatwashers Grade 8 that were rem
132. t of Bosch warranty the Ford dealer is to be charged for the exchange pump but the cost is not to exceed the actual repair cost of the original pump For a fuel injection concern on a FNH or FD engine the Ford dealer should perform the appropriate diesel engine diagnostic procedures and repair the system as required When necessary the Ford Heavy Truck Technical Hotline 800 826 4694 can be contacted for assistance in diagnosing and or repairing hard to resolve concerns If the fuel injection pump is removed for service the Ford dealer should provide the local Bosch DSD information on the engine symptoms and a time frame when the repaired injection pump is needed The Bosch DSD will follow the previously stated policies to ensure the repair is completed promptly If however there is a delay due to a technical or part availability issue then the Ford dealer should first contact the Ford Heavy Truck Hotline for assistance The Hotline will work with Bosch to help resolve the concern If additional assistance is needed the Ford dealer can work directly with Bosch by contacting Mr Ray Chorostecki Bosch Project Manager at 708 865 5354 or Mr Thomas Novak Bosch National Sales Manager 708 865 5260 OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS INFORMATION ONLY OASIS CODES 404000 601300 602300 603300 617400 618400 95 7 Publication Date APRIL 10 1995 Article No Air Cleaner Availability Of New Service Kit For Retain
133. tic transmission will use a rubber type damper F3HZ 6312 B The AT 545 transmission design allows it to dampen the engine vibration noise similar to what a viscous damper would therefore allowing the use of the rubber crankshaft damper All other transmissions manual and automatic use a viscous damper F3HZ 6312 G During the early build period of the FD1060 engine two 2 different styles of crankshaft dampers and adapters were used However all service replacement viscous crankshaft dampers and adapters will be the latest level F3HZ 6312 G damper F3HZ 6A329 A adapter Some early production FD1060 engines that were to be equipped with the viscous crankshaft damper were instead built with a rubber crankshaft damper If the engine serial number the serial number is located on the engine data plate which is attached to the front gear housing is between 44726807 and 44731926 and the vehicle is equipped with a transmission other than the AT 545 then it probably has the incorrect rubber damper Use of the rubber damper in applications that require a viscous damper can increase the noise level of the engine If a particular engine is within the serial number range and there is a concern with the engine noise level the original crankshaft damper should be replaced with the viscous damper PART IDENTIFICATION The rubber damper assembly is one piece The viscous damper assembly consists of three 3 separate pieces damper adapter and drive be
134. ticle 95 25 14 WIRE HARNESS INSTALLATION SOLENOID AIR VALVE INDEX TEMP TIMER CONTROL COMPRESSOR HIGH PRESSURE SWITCH F3HT 14808 AA Y N 77 ENGINE REFERENCE FIGURE 2 TYPICAL AIR LINE INSTALLATION AND ROUTING CONNECTORS SOLENOID AIR VALVE _ m e a amm emu SL 4 4 TUBE SOLENOID AIR VALVE TO VS pe 4 O D TUBE AIR MANIFOLD TO SOLENOID AIR VALVE A E CONNECTOR FIGURE 3 VIEW IN DIRECTION OF ARROW 2 SHEET 3 OF 3 nat ON OFF FAN CONTROL SYSTEM REPLACEMENT F2H2 8C609 A FOR L 9000 SERIES WITH BENDIX CLUTCH AND AIR CONDITIONING INSTALLATION INSTRUCTIONS TB 3317 B Figure 7 Article 95 25 14 ON OFF FAN CONTROL SYSTEM REPLACEMENT KIT F2HZ 8C609 B FOR L 9000 SERIES WITH BENDIX CLUTCH WITHOUT AIR CONDITIONING INSTALLATION INSTRUCTIONS Kit Contents Part Number F2HZ 8C609 B FOHZ 10884C Index Temperature Timer Soera DT Bracket solenoid air vawe mounting 1 56721252 Bots amp iBxiOi solenidtobrace 2 a7essos2 NutS amp iB soenodtotrace 2 5 452 Bolt1 4 20x99 bracket to hood stabilize 2 33777 32 7 Nut 174 20 bracket to hood stabtize 2 FaHT 14870 AA JumperPugConnector 383933510 1 4 Air Inlet Adapter 0 4 1 4 Air Line 30 Length sol
135. tlined in the Service Manual Section 04 01 6 Install wheels and torque nuts to the specifications listed in the Service Manual Section 04 01 OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 301000 702000 702100 703000 703400 95 17 Publication Date AUGUST 28 1995 Reduced Power Loss Of Turbocharger Boost Charge Air Tubing Chafing On Article No Generator Bracket Detroit Diesel Series 60 Engines 95 17 12 Engine Detroit Diesel Series 60 Charge Air Tubing Chafing On Generator Bracket MEDIUM HEAVY TRUCK 1994 95 L SERIES ISSUE On some vehicles equipped with the Detroit Diesel Series 60 engine the charge air intake tube may be out of position This may allow the tube to chafe on the generator support brackets possibly perforating the tube and creating a loss of turbocharger boost pressure and reduced engine power ACTION Reposition or replace the charge air tube as required Refer to the following Service Procedure for details SERVICE PROCEDURE 1 Check the charge air tubing from the turbocharger to the charge air cooler for clearance between the tubing and the generator and generator mounting fasteners 2 If tubing shows signs of contacting any engine component the charge air tubing and turbocharger compressor housing may need to be adjusted First check that the turbocharger compressor housing is properly
136. ush order 48 hours processes are used To obtain VOR service a Ford servicing dealer should communicate to the Bosch Diesel Service Dealer DSD the level of urgency or the time the injection pump is needed for installation on the engine The DSD will then employ the VOR system if necessary BOSCH VOR POLICY AND PROCEDURE e The VOR service is to be used in unit down repairs only e The quantities of parts ordered may be limited to one 1 repair The VOR service charges will not be passed on to the Ford Dealer the Ford dealer will not be charged any additional amount for the parts or repair of the injection pump when the VOR program is used VOR orders will be shipped the same day if called in by 3 30 PM CST and the part is in the Atlanta Distribution Center Inthe event the part is not available at the Atlanta Distribution Center it will be obtained from an alternative source DSD inventory Bosch Germany Charleston or Brazil The VOR part will be shipped as soon as possible however in these cases Bosch cannot guarantee 24 hour service Ford Customer Service Division has requested and Bosch has implemented a 48 hour service by the Bosch DSD network If an injection pump cannot be repaired and returned within two 2 working days the Ford dealer can request an exchange pump The exchange pump will be Free of Charge if the pump is still within the Bosch warranty exchange pumps are subject to approval by Bosch If the pump is ou
137. ut of the way Install the wire harness 19D887 to power ground temp timer switch 108843 and the air solenoid valve 8 180 See Figures 1 and 2 Remove the 1 4 air line leading from tha air manifold on the cab to the fan stat BK612 Remove the 1 8 air line and fittings between the fan stat BK612 and the fan clutch 8 627 Also remove the 1 8 air inlet adapter from the fan clutch Replace it with the 1 4 air inlet adapter 383833 5102 included in the repair kit I S 6328A SHEET 1 OF 3 ON OFF FAN CONTROL SYSTEM REPLACEMENT KIT 2 2 8 504 FOR L 9000 SERIES WITH BENDIX CLUTCH W O AIR CONDITIONING INSTALLATION INSTRUCTIONS CPA 1933 FORD MOTOR COMPANY DEARBORN MICHIGAN 48121 9 93 TB 3318 B Figure 8 Article 95 25 14 7 Replace the removed air lines with the 1 4 air line included in the kit Sea Figure 3 NOTE For non A C vehicles the Timer function of the Temp Timer switch is not used FORD HEAVY TRUCK FAN CLUTCH OPERATION WITH INDEX CONTROL SYSTEM FIELD FIX WITHOUT AIR CONDITIONING AIR FLOWS FROM THE AIR SUPPLY TO THE AIR SOLENOID VALVE WITH THE ENGINE COOLANT TEMPERATURE WITHIN NORMAL RANGE ELECTRIC CURRENT FLOWS THROUGH THE COOLANT TEMPERATURE SWITCH TO THE AIR SOLENOID VALVE THE CURRENT OPENS THE NORMALLY CLOSED AIR SOLENOID VALVE SO THAT AIR 15 SUPPLIED TO THE FAN CLUTCH DISENGAGING IT WHEN THE TEMPERATURE SWITCH OPENS THE ELECTRICAL CIRCUI
138. vehicles This could result in an early countershaft bearing concern The affected transmission was installed on Ford vehicles as a DSO option Direct drive and 13 speed transmissions are not involved ACTION Call the Rockwell Customer Service Center Hotline 800 535 5560 USA and Canada for information regarding this program Rockwell Transmission will repair the failed transmissions with factory remanufactured transmissions under warranty For vehicles domiciled in Australia contact Rockwell International located in Sunshine Victoria Australia OTHER APPLICABLE ARTICLES NONE SUPERSEDES 95 6 21 WARRANTY STATUS INFORMATION ONLY OASIS CODES 505000 597997 95 11 Publication Date JUNE 5 1995 Stall Or No Start Fuel Shutdown Solenoid Wiring Chafing On Fuel Injector Lines Vehicles Built Before 10 19 94 With FD1060 Engine And Bosch P7100 Fuel Injection Pump Wiring Fuel Shutdown Solenoid Stall Or No Start Wires Rubbing On Fuel Injector Article No Lines Vehicles Built Before 10 19 94 With FD1060 Engine And Bosch P7100 Fuel 95 11 15 Injection Pump Fuel Shutdown Solenoid Stall Or No Start Wiring Chafing On Fuel Injector Lines Vehicles Built Before 10 19 94 With FD1060 Engine And Bosch P7100 Fuel Injection Pump MEDIUM HEAVY TRUCK 1993 95 CARGO SERIES F amp B SERIES L SERIES ISSUE The Fuel Shutdown Solenoid wiring harness may rub against the Fuel Injector Lines and create a short circuit
139. very Instrument Panels Article No Heater Revised Blower Motor Switch Vehicles Equipped With City Delivery 95 11 16 Instrument Panels MEDIUM HEAVY TRUCK 1970 90 L SERIES ISSUE A revised heater blower switch with a retrofit wiring connector has been developed ACTION Splice the wiring assembly into the existing harness This will allow for the installation of the revised heater blower switch Refer to the following procedure for service details SERVICE PROCEDURE 1 Remove the climate control assembly referring to the appropriate Service Manual Remove the heater blower switch and disconnect the electrical connector Cut the blower switch wiring approximately 4 6 102 152mm from the end of the connector Strip all cut wiring 0 3 7 6mm Match the color coding of the new assembly to the existing wiring from the main harness NOTE ON OLDER VEHICLES A CIRCUIT NUMBER AND COLOR CHANGE IS APPARENT ON ONE 1 WIRE THESE VEHICLES WILL NOT HAVE CIRCUIT 57 BLACK TO THE BLOWER SWITCH INSTEAD THEY WILL HAVE CIRCUIT 399 BROWN IF ENCOUNTERED SPLICE CIRCUIT 399 BROWN OF THE EXISTING HARNESS INTO CIRCUIT 57 BLACK OF THE NEW WIRING HARNESS Insert the corresponding wires into the wiring assembly F5HZ 14A411 A Crimp all connectors Apply heat to all of the dual wall butt splice until the insulation shrinks and adhesive flows from each end Remove the blower motor switch and replace with new switch F
140. w on the gear pressure port and align the elbow so that its centerline is parallel to the truck s side rail Attach the pressure line and return line to the gear NOTE TAKE CARE NOT TO CRIMP THE LINES REFER TO FIGURE 4 RETURN HOSE PRESSURE HOSE AND ELBOW Figure 4 Article 95 15 15 8 Fill the reservoir with Motorcraft MERCON Multi Purpose Auto Transmission Fluid XT 2 QDX E4AZ 19582 B or equivalent 9 Tocheck system for leaks remove air from the system and check power assist through range of wheel articulation Start engine rotate wheels from wheel stop to stop DO NOT HOLD THE WHEELS AGAINST THE STOPS FOR LONGER THAN 5 SECONDS If power assist is significantly reduced before reaching the stop bolts check stop bolts for proper setting If the bolt setting is correct or the setting has been corrected and stop bolts are not contacted refer to the Truck Service Manual Steering Diagnosis and Testing Section REPLACEMENT OF C300N STEERING GEAR WITH ROSS TAS40 55 STEERING GEARS APPLICATION F B SERIES WITH 6000 7000 LB FRONT AXLE BENDIX C300N TO ROSS TAS40 8000 9000 LB FRONT AXLE BENDIX C300N TO ROSS TAS55 PROCEDURE 1 Thoroughly clean off all outside dirt especially around fittings CAUTION DO NOT STEAM CLEAN OR HIGH PRESSURE WASH HYDRAULIC STEERING ASSEMBLIES OR FORCE ABUSE CLOSELY FITTED PARTS DAMAGE WILL RESULT 2 Disconnect the power steering pressure and return lines at the gear 3 D

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