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TSB 97-3-10 - Ford Powerstroke Forum

1. produce similar noises include e transfer case skid plate e leaf spring bushings e steering intermediate shafts e shock bolts bumper brackets e brakes Other Service Bulletins have been published to address the proper repair of these concerns DIAGNOSTIC PROCEDURE 1 INTERVIEW THE CUSTOMER a Understand the customer s description of the noise and of the conditions under which it is heard b Road test the vehicle with the customer to fully understand where how and when the noise occurs 2 DUPLICATE THE NOISE CONCERN a Drive the vehicle around for at least 15 minutes to warm up and exercise the frame joints so that any frame noise is more likely to be repeatable in the garage or on the road b Identify the conditions in which the noise is repeatable Does the noise occur e While parked and turning the wheels lock to lock e Only when driving While going straight over bumps e While on a lift with the suspension unloaded e Only when the brakes are applied PAGE 1 Article No 97 3 10 Con d c ldentify tne general location of the noise Can you feel the noise in the floorboard or the steering wheel Refer to Figure 9 for likely locations for the noise NOTE USE CHASSIS EARS AND OR A STETHOSCOPE TO DETERMINE THE LOUDEST POINT OF THE NOISE IF THE NOISE IS REPRODUCIBLE WHEN STATIONARY PUT THE VEHICLE ON A DRIVE ON LIFT AND FEEL FOR ANY MOVEMENT OR VIBRATION AT THE JOI
2. three 3 bolts nuts at the crossmember to frame siderail at the wraparound side Figure 7 Number 1 b Torque the gusset to frame bolts Figure 7 Number 2 PAGE 4 c Torque the crossmember to frame bolts Figure 7 Number 3 d Torque the gusset to crossmember bolts Figure 7 Number 4 7 lfthe vehicle has a double gusseted crossmember Figure 8 torque each grouping of fasteners in the order listed in the following Substeps to 70 10 5 Nem 52 8 Ib ft and repeat for the other side a Torgue the gusset to frame bolts Figure 8 Number 1 b Torgue the crossmember to frame bolts Figure 8 Number 2 c Torgue the gusset to crossmember bolts Figure 8 Number 3 8 Reattach transmission a Lower the transmission b Reattach the transmission using new Nuts N621945 S2 and torgue to 95 15 Nem 70 11 Ib ft 9 Inspect gusset crossmember joint a Visually inspect the joint between the gusset and crossmember If all fasteners have been torgued properly and any gap exists between the two shim joint with washers b Reattach the gusset with new Bolts N802114 S2 and Nuts N800937 S427 torgued to 70 10 5 Nem 52 7 Ib ft NOTE ON HEAVY DUTY VEHICLES IT MAY BE NECESSARY TO UPGRADE THE REPLACEMENT FASTENER TO A 9 16 GRADE 8 TOROUE PREVAILING NUT 34990 S2 AND BOLT 58698 S2 TO 190 4 Nem 140 3 LB FT E Radius Arm Brackets NOTE USE WARRANTY DEALER CODING 3B095
3. AS BASIC PART NO 1 Inspect and retorgue all radius arm bracket bolt s to 135 20 Nem 100 15 16 1 NOTE IF THE BOLT IS VERY LOOSE AND THE BRACKET IS NOT CLAMPED TIGHTLY INSPECT Article No 97 3 10 Con d THE FRAME AND BRACKET HOLES FOR ELONGATION IF A BRACKET HOLE IS ELONGATED THE BRACKET MUST BE REPLACED IF A FRAME HOLE IS ELONGATED THE ENTIRE FRAME MUST BE REPLACED OR THE FRAME AND BRACKET HOLES MUST BE DRILLED OUT TO A LARGER SIZE NOT TO EXCEED 15mm 19 32 AND A LARGER AND BOLT MUST BE INSTALLED 2 Inspect the rivets for looseness Replace any loose or poorly seated rivets using the following procedure NOTE MOST OFTEN THE NOISE CAN BE ELIMINATED BY REPLACING ONLY THE MIDDLE RIVET OF THE THREE 3 SECURING THE BRACKET a Remove damaged or loose rivet e Drill a 3 175mm 1 8 hole through the rivet e Redrill the same hole through the shank of the rivet with a 9 525mm 3 8 drill e Remove the rivet head with an air chisel e Drive out the rivet with a punch and hammer CAUTION DO NOT REMOVE THE FASTENER WITH A CUTTING TORCH BECAUSE DAMAGE TO THE FRAME STRUCTURE IS LIKELY TO RESULT b Line ream the hole to the replacement bolt size of 12 7mm 1 2 c Clean hole of burrs after reaming so that the bolt head and nut will seat properly d Install a new Bolt N802210 S2 and Nut N800937 S427 and torque to 133 20 Nem 98 15 lb ft F Spring Towers NOTE USE WAR
4. NTS 3 INSPECT FRAME BOLTS FOR PROPER INSTALLATION TORQUE Inspect and tighten all front end components which bolt to the frame to confirm that they are at the proper torque refer to the Repair Procedure section of this article for proper torque requirements This includes but is not limited to e radius arm bracket bolts e axle pivot bracket bolts e transmission crossmember bolts spring tower bolts 4 INSPECT THE FRAME RIVETS e Inspect all riveted frame and suspension components in the general area of the noise for loose or improperly seated rivets NOTE TAP THE RIVETS WITH A SMALL HAMMER WHEN A RIVET IS NOT INSTALLED PROPERLY IT WILL MAKE A DIFFERENT SOUND THAN A SNUG RIVET Service identified rivets according to the procedure listed in the Repair Procedure section 5 TEST DRIVE THE VEHICLE Road test the vehicle again to duplicate the concern If the noise is still present proceed to the next Step PAGE 2 6 TEST JOINTS TO LOCATE NOISE Use a small pry bar as a wedge between components suspected of causing the noise By pounding the wedge into a joint or behind a bracket the noise should change or be eliminated if the noise is coming from that location NOTE USING A STETHOSCOPE OR CHASSIS EARS WILL HELP TO IDENTIFY ANY NOISE CHANGE e f the source of the noise is identified proceed to the Repair Procedure section e If the source of the noise has not been identified by
5. PLATE ATTACHMENTS AND SHOULD BE INVESTIGATED IN PAGE 3 Article No 97 3 10 Con d CONJUNCTION WITH THIS REPAIR PROCEDURE 1 Remove transmission weight a Remove bolts attaching transmission mount to the crossmember b Lift the transmission to remove any load to the crossmember The crossmember should now be completely loose NOTE YOU MAY NOTICE THE FRAME RAILS TWIST SLIGHTLY AND RELAX AFTER THIS NEXT STEP 2 Loosen crossmember a Loosen all bolts attaching the crossmember to the frame siderails b Loosen all bolts attaching the crossmember gusset s to the crossmember and to the frame siderails The crossmember should now be completely loose 3 the steering wheel lock to lock and then straighten the wheels This helps to remove any stress in the frame 4 Install new crossmember fastening hardware one at a time and replace each nut and bolt with a new Nut N800937 S427 and Bolt N802114 S2 and leave them loosely assembled until all crossmember and gusset fasteners have been replaced NOTE IT IS IMPERATIVE THAT THE FOLLOWING TIGHTENING SEQUENCE BE FOLLOWED 5 Secure the crossmember attaching hardware Determine which style of crossmember the vehicle is equipped with and follow Step 6 or 7 6 If the vehicle has a wraparound style crossmember Figure 7 torque each grouping of fasteners in the order listed in the following Substeps to 70 10 5 Nem 52 8 lb ft a Torque all
6. RANTY DEALER CODING 5A306 AS BASIC PART NO Inspect the rivets for looseness Replace any loose or poorly seated rivets using the following procedure 1 Remove damaged or loose rivet a Drill a 3 175mm 1 8 hole through the rivet b Redrill the same hole through the shank of the rivet with a 9 525mm 3 8 drill c Remove the rivet head with an air chisel d Drive out the rivet with a punch and hammer CAUTION DO NOT REMOVE THE FASTENER WITH A CUTTING TORCH BECAUSE DAMAGE TO THE FRAME STRUCTURE IS LIKELY TO RESULT 2 Line ream the hole to the replacement bolt size of 11 113mm 7 16 3 Clean hole of burrs after reaming so that the bolt head and nut will seat properly 4 Install a new Bolt 56561 S2 and Nut 382400 2 and torgue to 89 13 Nem 66 10 Ib ft G Front Leaf Spring Brackets NOTE USE WARRANTY DEALER CODING 5340 AS BASIC PART NO Inspect the rivets for looseness Replace any loose or poorly seated rivets using the following procedure 1 Remove damaged or loose rivet Drill a 3 175mm 1 8 hole through the rivet b Redrill the same hole through the shank of the rivet with a 8 731mm 11 32 drill c Remove the rivet head with an air chisel Drive out the rivet with punch and hammer CAUTION DO NOT REMOVE THE FASTENER WITH CUTTING TORCH BECAUSE DAMAGE TO THE FRAME STRUCTURE IS LIKELY TO RESULT 2 Install a new Bolt 58634 2 two 2 Washer
7. T TO REAR TO PROVIDE BEST CLAMPING PRIOR TO TACK WELD TACK WELD NUT TO U li SIDE PLAN VIEW BOLT AFTER TORQUE EXTENDED FLANGE STEERING GEAR LINER THIS SIDE ONLY 2 SPOTS TB 2242 A Figure 6 Article 97 3 10 PAGE 8 Article No 97 3 10 Con d FASTENER TORQUE ORDER WRAPAROUND STYLE CROSSMEMBER FRONT OF VEHICLE TB 4992 A Figure 7 Article 97 3 10 FASTENER TORQUE ORDER DOUBLE GUSSETED CROSSMEMBER FRONT OF VEHICLE TB 4993 A Figure 8 Article 97 3 10 PAGE 9 V 60cr amp 1l eysregy en 5004 ejdniny 40 ON 100 4 SSION DI 1894 uojsusdsns sduing 1940 wens Butaug SNOLLIGNOD SNILVH3dO 4907 0 4907 fueuoneiS SAWILAWOS X X EGRE iqi EIE EE NS pum ED NP Eee EN Ecl diuspiW 14044 W I 11014 3SION NALIO LSOW X uoisuedsng jeuio JOYE ey 104021g Buuds 497 10014 Buuds JeJ0B1G SNIPEH W O UOISSILUSLEJ 10101504 W O 1940 JeueiseJ yon LNANOdWOD Figure 9 Article 97 3 10 PAGE 10
8. and insert it into the newly reamed hole NOTE ON VEHICLES WITH QUAD SHOCK ABSORBERS IT MAY BE NECESSARY TO REMOVE THE SHOCK SPRING TOWER TO GAIN ACCESS TO THE WINDOW IN THE SIDERAIL b Install the washer and nut and torque nut to 190 4 Nem 140 3 lb ft Turn the wheels lock to lock several times to seat the joint and retorque Tack weld the nut to the bolt after tightening CAUTION DO NOT WELD THE NUT WASHER TO THE FRAME NOTE ON HEAVY DUTY VEHICLES IT MAY BE NECESSARY TO UPGRADE THE REPLACEMENT FASTENER TO A 5 8 GRADE 8 TORQUE PREVAILING NUT 34991 S2 BOLT 58720 S100 AND TWO 2 WASHERS 44881 S2 TORQUED TO 250 6 8 Nem 185 5 LB FT B Other 1 Crossmember Rivets NOTE USE WARRANTY DEALER CODING 5020 AS BASIC PART NO Follow the Huck Fastener Repair Procedure A listed in this article for cold head rivets and replace the rivet with a 9 16 Grade 8 torque prevailing Nut 34990 S2 with a Washer 44880 S2 and a Grade 8 Bolt 58698 S2 with a Washer 44880 S2 C Other Rivets NOTE USE WARRANTY DEALER CODING 5004 AS BASIC PART NO Follow TSB 96 15 11 for proper rivet replacement procedure D Transmission Crossmember NOTE USE WARRANTY DEALER CODING 5060 AS BASIC PART NO This procedure should be done on flat ground or on a drive on lift with the wheels pointed straight and full weight resting on the wheels NOTE A SIMILAR NOISE CAN OCCUR AT THE TRANSFER CASE SKID
9. e FRAME POPPING CREAKING FASTENER REPLACEMENT Article No 97 3 10 e NOISE POPPING CREAKING FRONT FRAME OR SUSPENSION BRACKETS FORD 1980 1997 F 250 HD F 350 1988 1997 F SUPER DUTY F 47 This TSB article is being republished in its entirety to include vehicles built through the 1997 model year and to update the Transmission Crossmember Service Procedure ISSUE A popping creaking sound may come from the area of the front frame or suspension brackets This may occur because of a slip stick motion at a loose rivet or bolt in a frame crossmember or a suspension bracket radius arm spring tower spring shackle etc ACTION Use the following Diagnostic Procedure to determine the location of the noise Replace the suspected fastener s by referring to the following Repair Procedure for details SOURCES OF VARIOUS FRONT UNDERBODY NOISES Various front underbody noises may originate from several different sources and are often difficult to locate and diagnose Common noise locations include e 1 engine crossmember rivets primarily the rivet or huck fastener at the lower left front behind the steering gear loose or improperly seated spring shock tower rivets bolts e loose or misaligned transmission crossmembers loose or improperly seated front leaf spring bracket rivets loose radius arm brackets loose axle pivot brackets 1980 1996 BRONCO F 150 F 250 LD Other underbody areas that
10. epair Repair D Not To Be Used With Operation D 1 Crossmember And Other Rivets Replace Two Repairs B And C 1 Crossmember And Other Rivets Replace Three Repairs B And C TIME 0 7 Hr 970310B 1 1 Hr 970310CA 0 9 Hr 970310CB 1 3 Hrs PAGE 6 970310CC 970310CT 970310C 970310D 970310E 970310FT 970310F 970310GT 970310G 970310HA 970310HB 970310HC 970310HT 970310H 9703101A 9703101B 9703101C 1 Crossmember And Other Rivets Replace Four Repairs B And C 1 Crossmember And Other Rivets Replace Five Or More Repairs B And C 1 Crossmember And Other Rivets Replace One Repairs B And C Transmission Crossmember Repair D Not To Be Used With Operation B Radius Arm Bracket Repair E Inspect And Check Fastener Torque Radius Arm Bracket Replace Both Repair E Not To Be Used With Operations G And GT Radius Arm Bracket Replace One Repair E Not To Be Used With Operations G And GT Radius Arm Bracket Rivet Replace Both Repair E Not To Be Used With Operations F And FT Radius Arm Bracket Rivet Replace One Repair E Not To Be Used With Operations F And FT Spring Tower Rivet Replace Two Repair F Spring Tower Rivet Replace Three Repair F Spring Tower Rivet Replace Four Repair F Spring Tower Rivet Replace Five Or More Repair F Spring Tower Rivet Replace One Repair F Front Leaf Spring Bracket Rivet Replace Tw
11. o Repair G Front Leaf Spring Bracket Rivet Replace Three Repair G Front Leaf Spring Bracket Rivet Replace Four Repair G 1 7 Hrs 2 1 Hrs 0 5 Hr 0 5 Hr 0 2 Hr 1 3 Hrs 0 7 Hr 0 9 Hr 0 5 Hr 1 0 Hr 1 4 Hrs 1 8 Hrs 2 2 Hrs 0 6 Hr 0 9 Hr 1 3 Hrs 1 7 Hrs Article No 97 3 10 Con d 97031017 Front Leaf Spring Bracket 2 1 Hrs Rivet Replace Five Or More Repair G 9703101 Front Leaf Spring Bracket 0 5 Hr Rivet Replace One Repair G 970310J Axle Pivot Bracket 0 2 Hr Inspect And Check Fastener Torgue DEALER CODING CONDITION BASIC PART NO CODE 38095 FOR REPAIR PROCEDURE E 96 3B178 FOR REPAIR PROCEDURE H 56 5004 FOR REPAIR PROCEDURE C 56 5020 FOR REPAIR PROCEDURE A 56 5020 FOR REPAIR PROCEDURE B 56 5060 FOR REPAIR PROCEDURE D 56 TB 2238 A 5340 FOR REPAIR PROCEDURE G 56 5A306 FOR REPAIR PROCEDURE Figure 2 Article 97 3 10 F 56 OASIS CODES 305000 390000 702000 702100 COLLAR TB 2239 A TB 2237 A Figure 3 Article 97 3 10 Figure 1 Article 97 3 10 PAGE 7 Article No 97 3 10 Con d 14 288mm 9 16 DIAMETER 1 HOLE LINE REAM THROUGH LINER FLANGE AND CROSSMEMBER TO MATCH EXISTING HOLE BEARING INSERT CROSSMEMBER LEFT SIDE BOTTOM FLANGE VIEW ALL MODELS 2240 2241 Figure 4 Article 97 3 10 Figure 5 Article 97 3 10 EXTENDED FLANGE STEERING GEAR LINE POSITION BOLT HEX HEAD WITH FLA
12. s 44877 S2 and a Nut 34987 S2 Torque to 62 15 Nem 46 11 Ib ft H Axle Pivot Brackets NOTE USE WARRANTY DEALER CODING 3B178 AS BASIC PART NO PAGE 5 Article No 97 3 10 Con d Inspect and retorque all axle pivot bracket bolts torgue values may vary by model refer to the appropriate light truck Service Manual for proper torgue specifications NOTE IF THE BOLT IS LOOSE AND THE BRACKET IS NOT CLAMPED TIGHTLY INSPECT THE FRAME AND BRACKET HOLES FOR ELONGATION IF A FRAME HOLE IS ELONGATED THE ENTIRE FRAME MUST BE REPLACED NO FRAME REPAIRS ARE AUTHORIZED ON THESE 1 CROSSMEMBER HOLES PART NUMBER PART NAME 34990 S2 Grade 8 Torque Prevailing Nut 9 16 44880 S2 Washer 9 16 Pk 12 58698 S2 Grade 8 Bolt 9 16 12x1 75 Pk 4 34991 S2 Grade 8 Torque Prevailing Nut 5 8 44881 S2 Washer 5 8 Pk 12 58720 S100 Grade 8 Bolt 5 8 Pk 4 N802114 S2 Bolt N800937 S427 Nut N621945 S2 Nut N802210 S2 Bolt 56561 S2 Bolt 382400 S2 Nut 58634 S2 Bolt 44877 S2 34987 S2 F6TZ 5D033 BA Low Friction Insert OTHER APPLICABLE ARTICLES 96 15 11 SUPERSEDES 96 4 11 WARRANTY STATUS Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992 96 Model Years Basic Warranty Coverage For All Others OPERATION DESCRIPTION 970310A Perform Diagnostics Includes Road Test Huck Fastener Replace Repair A Includes Additional Road Test And Transmission Crossmember R
13. the rive s head off with a hammer and flat chisel Figure 3 e Knock the sleeve out of the blind side with a 9 525mm 3 8 drift punch and hammer Figure 4 CAUTION DO NOT REMOVE THE FASTENER WITH A CUTTING TORCH BECAUSE DAMAGE TO THE FRAME STRUCTURE IS LIKELY TO RESULT 2 After removing the rivet verify the noise came from this location by pounding a wedge between the crossmember and the frame liner then driving the vehicle to reproduce the noise The wedge will lift the crossmember off of the inner frame liner and eliminate any noise if the lower left front 1 crossmember joint is the source of the noise 3 With the wedge still in place insert the Bearing Strip F6TZ 5D033 BA between the 1 crossmember and frame liner Align the strip approximately centered and extending well past the hole location Remove the wedge and drill a 11 113mm 7 16 diameter hole through the bearing strip 4 Line ream the existing hole through the liner frame flange and crossmember to 14 288mm 9 16 Figure 5 Remove any burrs after reaming NOTE TO PROPERLY REAM THE HOLE ON A VEHICLE WITH LEAF SPRINGS THE SPRING MUST BE REMOVED TO PROVIDE VERTICAL ACCESS TO THE RIVET HOLE 5 Install a 9 16 Grade 8 torque prevailing Nut 34990 S2 with a Washer 44880 S2 and a Grade 8 Bolt 58698 S2 with a Washer 44880 S2 Figure 6 a Slide the bolt and washer into the window opening on the outside of the frame siderail
14. this Step investigate other non frame or suspension sources and or proceed to the next St ep 7 SERVICE THE VEHICLE a If the noise has been identified proceed to the specific component section in the Repair Procedure b If the noise source has not been identified refer to Figure 9 for general noise locations operating conditions and number of occurrences Proceed with repairing the identified components REPAIR PROCEDURE A THROUGH H A Huck Fastener Lower Left Front 1 Crossmember Rivet Replacement This procedure should be done on flat ground or on a drive on lift with the wheels pointed straight and full weight resting on the wheels This fastener could be either a standard cold head rivet in light duty applications or a large huck bolt which has the appearance of a large pop rivet NOTE USE WARRANTY DEALER CODING 5020 AS BASIC PART NO 1 Remove damaged or loose rivet COLD HEAD RIVETS Drill a 3 175mm 1 8 hole through the rivet e Redrill the same hole through the shank of the rivet with a 9 525mm 3 8 drill e Remove the rivet head with an air chisel e Drive out the rivet with a punch and hammer Article No 97 3 10 Con d HUCK RIVETS Use a flat chisel and hammer or air chisel to split the exposed collar of the huck fastener Figure 1 e Knock the rivet pin out of the blind side with a 6 35mm 1 4 drift punch and hammer Figure 2 e Cut

TSB 97-3-10 - Ford Powerstroke Forum

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