1995 Ford F-150-F-250-F-350-Bronco-F-Super Duty Powertrain-Drivetrain

Group Index INTRODUCTION
Group 00 SERVICE INFORMATION
ENGINE AND TRANSMISSION

Group 02
MOUNTING
Group 03 ENGINE .
Table -of Group 05 DRIVELINE
Contents
Powertrain, Group 07 TRANSMISSION
Drivetrain
Group 08 CLUTCH
Group 09 EXHAUST SYSTEM
IAII rights reserved. Reproduction by any

means, electronicor mechanical, including
Group 10 FUEL SYSTEM
.photocopying, recording, or by any
information storage and retrieval system or
translation in whole or part is not permitted
without written authorization from Ford
Motor Company.
INDEX/IMPORTANT
Copyright © 1994, Ford Motor Company
INFORMATION
DAVE GRAHAM INC. - 2014
ALL RIGHTS RESERVED
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ALL RIGHTS RESERVED
INTRODUCTION
•
Important Safety Notice
Appropriate service methods and proper repair procedures are essential for the safe, reliable
operation of all motor vehicles as well as the personal safety of the individual doing the work.
This Service Manual provides general directions for accomplishing service and repair \lJork
with tested, effective techniques. Following them will help assure reliability.
There are numerous variations in procedures, techniques, tools, and parts for servicing
vehicles, as well as in the skill of the individual doing the work. This Manual cannot possibly
anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone
who departs from the instructions provided in this Manual must first establish that he
compromises neither his personal safety nor the vehicle integrity by his choice of methods,
tools or parts.
Notes, Cautions, and Warnings

As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS.
Each one is there for a specific purpose. NOTES give you added information that will help you to
complete a particular procedure. CAUTIONS are given to prevent you from making an error that
could damage the vehicle. WARNINGS remind you to be especially careful in those areas where
carelessness can cause you personal injury. The following list contains some general WARNINGS
that you should follow when you work on a vehicle.
• Always wear safety glasses for eye protection.

• Use safety stands whenever a procedure requires you to be under the vehicle.
• Be sure that the ignition switch is always in the OFF position, unless otherwise required by the
procedure.
• Set the parking brake when working on the vehicle. If you have an automatic transmission or
automatic transaxle, set it in PARK unless instructed otherwise for a specific ,operation. If you
have a manual transmission or manual transaxle, it should be in REVERSE (engine OFF) or
NEUTRAL (engine ON) unless instructed otherwise for a specific operation. Place wood blocks
(4" x 4" or larger) against the front and rear surfaces of the tires to provide further restraint
from inadvertent vehicle movement.
• Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide.
• Keep yourself and your clothing away from moving parts when the engine is running, especially
the drive belts.
• To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tail pipe, three-way catalytic converter and muffler.
• Do not smoke while working on a vehicle.
• To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before
beginning to work on a vehicle.
• If it is necessary to work under the hood, keep hands and other objects clear of the radiator fan
blades! Your vehicle may be equipped with a cooling fan that may turn on, even though the
ignition switch is in the OFF position. For this reason care should be taken to ensure that the
radiator electric motor is completely disconnected when working under the hood when engine is
not running.

ALL RIGHTS RESERVED
•

ALL RIGHTS RESERVED
HOW TO
USE THIS
ANUAL
SUBJECTS COVERED IN THIS MANUAL 1
HOW THIS MANUAL IS ORGANIZED ~.~, ~ ~................................. 1

Group 1
Section 2
Page : 3
HOW TO FIND MATERIAL IN THIS MANUAL : 3
HOW TO USE EACH SECTION '......................... 3
WHAT TO DO IF YOU DISCOVER AN ERROR 4
..
TECHNICAL
PUBLICATIONS DEPARTMENT
Ford Customer Service Division "f
l··

ALL RIGHTS RESERVED
Subjects Covered in This Manual
This 1995 Service Manual covers normal service repairs and maintenance for
vehicles sold in the United States and Canada:
A separate publication, the 1995 Powertrain Control/Emissions Diagnosis Manual for all
vehicles except those with Caterpillar and Cummins engines covers:
• Engine Controls and Diagnosis

• TransmissionlTransaxle Controls and Diagnosis
• Emissions Diagnosis
How This Manual is Organized

This manual is organized by Group, Section, and Page.
Group
A Group covers a specific portion of the vehicle. The first set of numbers on each page
indicates the Group.
~O·1
GROUP ~ -
NUMBER
GROUP
SECTION TITLE PAGE

BODY
SECTION TITLE
01 PAGE
BODY, GENERAL SERVICE Ol-00·1 HANDLES, LOCKS, LATCHES AND
FRONT END BODY PANELS MECHANISMS O1·14·1
AND STRUCTURE 01·02-1 FRONT WINDOW WIPERS 01 .. 16A·1
NOTE: A Group usually contains more than one Section.

ALL RIGHTS RESERVED
The eight Groups found in this manual are:
00 - Service Information
02 - Engine and Transmission Mounting
03 - Engine
05 - Driveline
07 - Transmission
08 - Clutch
09 - Exhaust System
10 - Fuel System
Section
Each Section covers a component or system. The second set of numbers on each page
indicates the Section.
If the vehicle has more than one type of component, such as two types of engines or power
steering systems, alphabetical suffixes are used.
DIAGNOSIS AND TESTING

ERATION (continued)
, heel hub bearings, wheel
Ax.le shafts. wheel hubs, N ric shift unit and the
hub grease ~eals~ .~e e'~ct n be r~p'aced without
To assist in locating a subject, whenever feasible, Section titles have the subject first,
followed by a descriptive word(s).
• Suspension, Computer Controlled
• Brake System, Anti-Lock

ALL RIGHTS RESERVED
Page
The third set of numbers indicates the Page in each Section.
ear shitt lever

the g d down tor \oW
ang e ~~""'_~Q noS\tions.
How to Find Material in This Manual

1. Locate the Group number in the Table of Contents. If you are not sure which Section
contains the information you need, look up the component/system in the
alphabetical index located in the back of this manual.
2. Locate the Section number by using the Group index located at the beginning of each
Group.
3. Locate the specific page by using the Section index at the beginning of each Section.
4. We have added a page footer that denotes the vehicle model year, vehicle line and
Service Manual print date.
How to Use Each Section

Each Section has a standard organization that consists of the following information:
Vehicle Application
Identifies the product (vehicle, model, engine, transmission, etc.) that the section applies to:
• Probe GT
• Aerostar and Ranger with integral carrier and 7.5 ring gear
• F- and B-Series vehicles equipped with FD-1460 Diesel engines
• Taurus with 3.0L/3.2L SHO engine
Description and Operation
Describes how the component or system works.
Diagnosis and Testing
Identifies how to pinpoint problems.
Removal and Installation
Describes how to remove and reinstall components and systems.

ALL RIGHTS RESERVED
Disassembly and Assembly
Lists how to take apart the component/system, and put it back together.
Adjustments
Describes how to perform in-vehicle adjustments.
Specifications
Summarizes all the specifications used in the Section.
Special Service Tools/Equipment
Lists all the Special Service Tools and Rotunda Equipment used in the Section.
Additional headings such as Service Procedures and Cleaning and Inspection may be used.
What to Do if You Discover an Error

If you discover a questionable procedure or if you have any suggestions for improving this
manual, please use one of the feedback forms provided in the front and back of this manual.
Your feedback is very important to improving Ford technical publications. You will get a
response to your concern. If necessary, a revision will be issued.
NOTE: The descriptions and specifications contained in this manual were in effect at
the time this manual was approved for printing. Ford Motor Company reserves the
right to discontinue models at any time, or change specifications or design without
notice and without incurring any obligation.

ALL RIGHTS RESERVED
00-01-1
GROUP I
SERVICE
INfORMATION
SECTION TITLE PAGE SECTION TITLE PAGE
IDENTIFICATION CODES ..•...•...•....••....•....•...••...•••...•.00-01-1 MAINTENANCE AND LUBRICATION .....•........•.....•.•....•00-03-1
SECTION 00-01 Identification Codes

SUBJECT PAGE SUBJECT PAGE
VEHICLE APPLICATION ............•.....••...••.........•..•.•...••00-01-1 VEHICLE IDENTIFICATION NUMBER ••••.••••..••.......•....•00-01-5
DESCRIPTION AND OPERATION VEHICLE CERTIFICATION LABEL (VC LABEL)
Build Date Stamp Location ....•......•.................•.•••.••00-Q1-4 CODeS
Certification Label •••..••..•••...••...•...•••..•••...•.•...•....••.00-01-2 Vehicle Type Codes •••••......•...••....••....••..••••..••..•..••.00-01-7
Vehicle Identification Number (VIN) ...•..........•••.•...••00-01-1
VEHICLE APPLICATION
F-Series and Bronco
DESCRIPTION AND OPERATION
Vehicle Identification Number (VIN) • Digits five, six and seven identify the model or line,
series, chassis, and cab or body type.
A seventeen-digit combination of numbers and letters
forms the vehicle identification number (VIN). The VIN • The eighth digit points out the particular engine
is stamped on a metal tab that is riveted to the found in the vehicle.
instrument panel close to the windshield. The VIN is • Digit nine is the VIN check digit.
viewable by looking through the front windshield on the
driver's side. The VIN is also found on the certification • The tenth digit identifies the model year of a
label. Ford-completed vehicle, or the model year of the
incomplete vehicle, if sold by Ford as an incomplete
By looking at the seventeen-digit VIN, a variety of vehicle.
information about the vehicle can be determined.
• The eleventh digit determines the assembly plant.
• The first three digits identify the manufacturer and
• Digits twelve through seventeen make up the
the vehicle make and type. sequence serial and warranty number. Digit twelve
• The fourth digit determines the gross vehicle weight uses the letter A until the production or sequence of
rating (GVWR-Class) and brake system for 99,999 units (digits thirteen through seventeen) is
Ford-completed trucks and MPV's. For buses and reached. Letter A then becomes B for the next
incompleted vehicles, the fourth digit determines the production sequence of vehicles.
brake system (only).
DAVE GRAHAM
1995 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain INC. - 2014
July 1994
ALL RIGHTS RESERVED
00-01-2 Identification Codes 00-01-2
DESCRIPTION AND OPERATION (Continued)
Refer to the code definition portion of this section for Certification Label
specific definitions of the numbers and letters of the
I vehicle identification number (VIN).
SAMPLEVIN
• The English certification label is attached to the
driver's side door or door lock pillar. The French
certification label is attached to the passenger's or
driver's side door or door lock pillar.
• The label contains the name of the manufacturer,
1 F T E F 25 H 5 S L A00001 the month and year of manufacture, the certification
--..-.. "-...-' ~ statement, and the vehicle identification number
(VIN).
• The label also contains gross vehicle weight ratings,
wheel and tire data, and information codes for
(D~@ @ ®®® ® ® @> ® @-@ additional vehicle data.
POSITIONS 1,2 AND 3 - MANUFACTURER, MAKE AND TYPE

(WORLD MANUFACTURER IDENTIFIER)
POSITION 4 - BRAKES SYSTEM/GVWR CLASS FOR FORD-
COMPLETED TRUCKS AND MPV'S. FOR BUSES
AND INCOMPLETE VEHICLES, BRAKE SYSTEM
(ONLY).
POSITIONS 5, 6, AND 7 - MODEL OR LINE, SERIES, CHASSIS,
CAB OR BODY TYPE
POSITION 8 - ENGINE TYPE
POSITION 9 - CHECK DIGIT
POSITION 10 - MODEL YEAR (FORD-COMPLETED VEHICLES)
POSITION 11 - ASSEMBLY PLANT
POSITIONS 12 THROUGH 17 - SEQUENCE NUMBER BEGINS AT
AODDD1. CONSTANT A UNTIL
SEQUENCE NUMBER OF 99,999 IS
REACHED, THEN CHANGES TO
CONSTANT B AND SO ON.
Y2378-P
DAVE
1995 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain, GRAHAM
Drivetrain INC.
- 2014
July 1994
ALL RIGHTS RESERVED
00-01-3' Identification Codes 00-01-3
Certification Labels
UNITED STATES BUILT u.S. BUILT, QUEBEC SALES

MFD. BY FORD MOTOR co. IN U.S.A. FAIR. AUX E-lJ PAR LA FORD MOTOR co.
DATE: 1ME GYWR: 8600 L8I39OO KG
fRONT GAWR: 2915 LS REAR GAWR: 6084 LB DATE: 9J95 PNBY: 1800 LB/3II1KG
1322 KG WITH 2769 KG WITH PNIE AV: 1716 L8 PNBE AR: 1014 L8
l T235185R16E TIlES l T236185R16E nRES 1707 KG AVEC 2759 KG
16x6K RIMS 16x6K RIMS l T235186R16E .... PNEUS~ l T236I86R16E
AT 51 PSI COLD AT 80 PSI COLD 16X6K "ANTES~ 16X6K
A 51 LBlPOI A FROID A 80 lJIIPOZ A FROID
ntIS VEtlCLE CO'*ORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY
STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE CE YBtICULE EST CONFORME A TOUTES ~S NORMES FEDERALES DE SECURITE
DES VA. EN VlGUEUR A LA DATE DE FA8R.INlQUEE Cl-DESSUS.
I
~: iiiiiiillllllllllll' ~~~
NIV: lFTHX25G6lKAOOOO2 F0195
TYPE: CAMION TOO4O
W7401
EXTERIOR PAINT COLORS
II 33tO
DSO
111111111111111111111
WB I TYPE GVW I BODY I TRANS AXLE I TAPE ISPRINGS AV
COUlEUR
AT
133 F257 AK4 G 35 CF
V FOTA-15204A10-AA EMPATT.
155
CANADIAN BUILT
FOR VEHICLES MFG. IN U.S.A. FOR QUEBEC, CANADA.
MFD. BY FORD MOTOR co. OF CANADA LTD.
DATE: W95 GVWR: . . L8I3IOO KG
FRONT GAWR: 2115 L8
1322 KG
REAR GAM: 1014 L8
WITH 2759 KG WITH
CANADIAN BUILT, QUEBEC SALES
l T235185R16E TIRES l T235185R16E TIRES
16X6K RIMS 16X6K .. FABR. PAR FORD DU CANADA UMITEE
AT 61 PSI COLD AT 80 PSI COLD
DATE: 9J95 PNBV: 1250 LSI 2834 KG
THIS VEfICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY PNBE AVArlf: 2100 L8 PNBE ARRIERE: 3100 LB
STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE 1270 KG AVEC 1723 KG
P235175R15Xl "'PNEUS~ P235175R15XL
~: iiiiiiiillllllllllil
W740t
WB I TYPE GVW I BODY I TRANS AXLE
II
I
l
I
TAPE
= 3390
DSO
I SPRING
15X6.OJK
A35 I.BIP()2 A FROID
NIV:
lYPE:
2FTEF15Y4LCAOOOO4
CAMION
....JANTES~ 16X6.OJK
A41 L.8IPOZ AFROID
CE YBlCULE EST CONFORME ATOUTES LES NORMES FEDERALES DE SECURITE

DES VA. EN VlGUEUR A LA DATE DE FABR.INIQUEE Cl-DESSUS.
I F0144
T0269
133 F257 AK4 G 35 CF
MADE IN CANADA v FOTA-15204A1O-BA
111111111111111111111 B2
N° COMM SPEC.
PONT BANDE RESSORT
CJ4 E H9 CD
MADE IN CANADA V FOTA-15204A1O-DA
DECAl. APPI.lEl> TO ALI.
('ANADIAN BUIl.T UNITS ANI> FOR VEHICLES MFG. IN CANADA FOR QUEBEC, CANADA.
ALL US.A. BUILT UNITS sou>
INCANA()A
INCOMPLETE VEHICLES (CANADA) INCOMPLETE VEHICLES (U.S.)

THE INCOMPlETE VEHICLE RATING DECAl IS INSTAllED ON THE DRIVER'S DOOR THE INCOMPLETE VEHICLE RATING DECAL IS INSTAlLED ON THE DRIVER'S DOOR
LOCK PILLAR IN PLACE OF THE SAFETY COMPlIANCE CERTIFICATION lABEl. lOCK PIlLAR IN PLACE OF THE SAFETY COMPLIANCE CERTIFICATION lABEl.
INCOMPLETE VEHICLE MANUFACTURED BY FORD MOTOR CO. OF INCOMPLETE VEHICLE MANUFACTURED BY

CANADA LTD. FORD MOTOR COMPANY
MADE IN CANADA MADE IN U.S.A.
DATE: W95 GVWR: 11000 lBI4989 KG DATE: 9195 GVWR: 11000 lB/4989 KG
FRONT GAWR: 4200 18 REAR GAWR: 8260 LB FRONT GAWR: 4200 LB REAR GAWR: 8250 LB
1905 KG WITH 3742 KG WITH 1905 KG WITH 3742 KG WITH
lT215185R16D TIRES LT215185R16D TIES LT215185R16D TIRES LT215185R16D TIRES
16x6IC RIMS 16x6K RNS 16x6K RIMS 16x6K RIMS
AT 58 PSI COLD AT 65 PSI COLD DUAL AT 58 PSI COLD AT 65 PSI COLD DUAL
YIN: 2FDKF37M6LCAOOOO8 VIN: 1FDKF37MOLKAOOOO5
W7401 111111111111111111111 881067 yy

111111111111111111111 410047
EXTERIOR PAINT COLORS DSO EXTERIOR PAINT COLORS DSO
WB I TYPE GVW I BODY I TRANS AXLE I TAPE ISPRINGS WB I TYPE GVW I BODY I TRANS AXLE I TAPE I SPRINGS
161 F379 AJ8 E 65 N Y 161 F379 AJ8 E 65 NY
V FOTA-15204A10-FA V FOTA-16204A1O-EA
V2666-N
DAVE
Drivetrain INC.
July 1994 - 2014
ALL RIGHTS RESERVED
00-01-4 Identification Codes , 00-01-4
Certification Label Codes
MFD. BY FORD MOTOR CO. IN U.S.A.

DATE: 2/95 GVWR: 6600 LB/2994 KG
REAR GA&'WR~:~400~4~LB~===:=====:1r~
FRONT GAWR: 3320 LB
1508KG
LT 215J85R 160
WITH
nRES
1S1SKG =
LT 215/85R 180
16 x 6K RIMS 16 x 6K
AT 51 PSI COLD AT 58 PSI COLD ...----------I~--l
TtIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEtICLE SAFETY
STANDARDS IN EFFECT ON THE DATE OF MANUFACIURE SHOWN ABOVE
:::TRUCK (~/(r(t) \~\~ FOO83

T0112~--"""-(~
4~-'--~7N
III111111111I11111111
9M
48~_-- .....-..,21
I
TRANS AXLE TAPE
E 342 B
<D NAME AND LOCATION OF @ VEHICLE IDENTIFICATION NUMBER @ MODEL CODE AND-GVW
MANUFACTURER (A) WORLD MANUFACTURER @ INTERIOR TRIM, SEAT AND BODY/CAB
IDENTIFIER TYPE
<2> DATE OF MANUFACTURE (B) BRAKE SYSTEM AND GROSS
VEHICLE WEIGHT RATING (GVWR) • TRANSMISSION CODE
@ FRONT GROSS AXLE WEIGHT
RATINGS IN POUNDS (LB) AND CLASS FOR FORD COMPLETED @) REAR AXLE CODE
KILOGRAMS (KG) TRUCKS AND MPV'S. FOR BUSES
AND INCOMPLETE VEHICLES, THE • FRONT AXLE CODE IF SO EQUIPPED
@ FRONT TIRE SIZE FOURTH DIGIT DETERMINES THE @ DISTRICT/SPECIAL ORDER CODES
BRAKE SYSTEM (ONLY). @ EXTERNAL BODY TAPE STRIPE CODE
@RIMSIZE (C) MODEL OR UNE, SERIES,
@ FRONT TIRE COLD PSI CHASSIS, CAB OR BODY TYPE o SUSPENSION, IDENTIFICATION CODES
(D) ENGINE TYPE (A) AUXJOPT. USAGE CODE (FRONT>
® GROSS VEHICLE WEIGHT RATING IN (E) CHECK DIGIT (B) FRONT SPRING CODE
POUNDS (LB) AND KILOGRAMS (KG) (F) MODEL YEAR (FORD-COMPLETE (C) AUXJOPT. USAGE CODE (REAR)
TRUCKS AND MPV'S) (D) REAR SPRING CODE
@ REAR GROSS AXLE WEIGHT RATING
IN POUNDS (LB) AND KILOGRAMS (KG)
(G) ASSEMBLY PLANT CODE 8 FRONT AXLE ACCESSORY RESERVE
(H) SEQUENCE NUMBER CAPACITY IN POUNDS
@ REAR TIRE SIZE @ VEHICLE TYPE e TOTAL ACCESSORY RESERVE
eRIMSIZE S EXTERIOR PAINT CODES OWO SETS CAPACITY IN POUNDS
OF FIGURES DESIGNATES A TWO-TONE)
@ REAR TIRE COLD PSI
~ WHEELBASE IN INCHES
W1017-e
Build Date Stamp Location For a build date of January 24, for example, the
The vehicle build date stamp is a four-digit number vehicle build date stamp reads 0124; for a build date
representing month and day of manufacture. On of October 21, the vehicle date stamp reads 1021.
Bronco and F-150, F-250, F-350 the vehicle build date
is stamped on the front surface of the radiator support
on the passenger's side of the vehicle.
DAVE GRAHAM
July 1994
ALL RIGHTS RESERVED
Yellow ink is normally used for the date stamp. When

the marking surface is painted the body color, the date
stamp will be marked in red ink. Units from the Ontario
Truck Plant (Code C) will be marked with silver ink.
VEHICLE IDENTIFICATION NUMBER
World Manufacturer Identifier
VIN POsmoNS 1, 2 AND 3
~E F25 H 5 S L AOOOO1
J
YIN
CODE MANUFACTURER MAKE TYPE
1FM FORD MOTOR COMPAN~ USA FORD MULTI PURPOSE PASSENGER VEHICLE (MPV)
1FT FORD MOTOR COMPAN~ USA FORD TRUCK (COMPLETED VEHICLE)
1FD FORD MOTOR COMPAN~ USA FORD INCOMPLETE VEHICLE (IV)
1FC FORD MOTOR COMPAN~ USA FORD BASIC (STRIPPED) CHASSIS
1FB FORD MOTOR COMPAN~ USA FORD BUS
1FF FORD MOTOR COMPAN~ USA FORD MOTOR VEHICLE EQUIPMENT WITHOUT ENGINE/POWERTRAIN (GLIDER)
2FM FORD MOTOR COMPANY OF CANADA, LTD. FORD MPV
2FT FORD MOTOR COMPANY OF CANADA, LTD. FORD TRUCK (COMPLETED VEHICLE)
2FD FORD MOTOR COMPANY OF CANADA, LTD. FORD INCOMPLETE VEHICLE
2FC FORD MOTOR COMPANY OF CANADA, LTD. FORD BASIC (STRIPPED) CHASSIS
2FB FORD MOTOR COMPANY OF CANADA, LTD FORD BUS
2FF FORD MOTOR COMPANY OF CANADA, LTD. FORD MOTOR VEHICLE eQUIPMENT WITHOUT ENGINEJPOWERTRAIN (GLIDER)
3FC FORD MOTOR COMPANY OF MEXICO FORD BASIC (STRIPPED) CHASSIS
Y2377.p
Brake System and GVWR Class
VlNPOSmON4
1FT ~ F25 H 5 S L AOOOO1

f
VlNCODE BRAKE SYSTEM GVWRClASS GVWRRANOE
A HYDRAULIC CLASS A NOT GREATER THAN 3,000 POUNDS
B HYDRAULIC CLASS B 3,001 - 4,000 POUNDS
C HYDRAULIC CLASSC 4,001 - 5,000 POUNDS
0 HYDRAULIC CLASS D 5,001 - 6,000 POUNDS
E HYDRAULIC CLASSE 6,001- 7,000 POUNDS
F HYDRAULIC CLASS F 7,001 - 8,000 POUNDS
G HYDRAULIC CLASSG 8,001 - 8,500 POUNDS
H HYDRAULIC 8,501 - 9,000 POUNDS
CLASSH
0,
J HYDRAULIC 9,001 - 10,000 POUNDS
K HYDRAULIC CLASS 3 10,001-14,000 POUNDS
L HYDRAULIC CLASS 4 14,001 - 16,000 POUNDS
M HYDRAULIC ClASS 5 <' 16,001 - 19,600 POUNDS
1995 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
VEHICLE IDENTIFICATION NUMBER (Continued)
Model or Line, Series, Chassis, Cab or Body Type
YIN POSmONS 5, 8 AND 7
1FT EI F2SIH S S L AOOOO1

I
+
VlNCODE II UNE II SERIES I~SI CAR OR BODY TYPE II VEHICLE TYPE
U15 BRONCO XL I 4x4 I BRONCO MPV
NOTE: ONE OF THE FOLLOWING OPTIONAL EXTERIOR NAMEPLATES (INDICATING HIGHER TRIM LEVELS) MAY ALSO BE AFFIXED
TO THE VEHICLE IN ADDITION TO THE BRONCO NAMEPLATE:
• XLT • EDDIE BAUER
SUPER CAB
REGULAR OR CREW
CAB CAB XL
F14 X14 F-SERIES F150 4x4 PICKUP - REGUlAR CAB/SUPER CAB TRUCK
F15 X15 F-SEIRES F150 4x2 PICKUP - REGULAR CAB/SUPER CAB TRUCK
F25 X25 F-SERIES F250 4x2 PICKUP - REGULAR CAB/SUPER CAB TRUCK
F26 X26 F-SERIES F250 4x4 PICKUP - REGULAR CAB/SUPER CAB TRUCK
F35 X35/W35 F-SERIES F350 4x2 PICKUP - REGULAR CAB/CREW CAB/
SUPER CAB TRUCK
F37 - F-SERIES F360 4x2 REGULAR CAB (CHASSIS CAB) IV
F36 W36 F-SERIES F350 4x4 PICKUP - REGULAR CABICREW CAB TRUCK
F38 - F-SERIES F350 4x4 REGULAR CAB (CHASSIS CAB) IV
F47 - F-SERIES F-SUPER DUlY 4x2 REGULAR CAB (CHASSIS CAB) IV
F53 - F-SERIES F-5UPER DUlY 4x2 RV BASIC STRIPPED CHASSIS IV
NOTE: MPV MEANS MULTI-PURPOSE PASSENGER VEHICLE. IV MEANS INCOMPLETE VEHICLE.
NOTE: ONE OF THE FOLLOWING OPTIONAL EXTERIOR NAMEPLATES (INDICATING HIGHER TRIM LEVELS) MAY ALSO BE AFFIXED
TO THE VEHICLE IN ADDITION TO THE F-SERIES NAMEPLATES:
• XLT • FLARESIDE • LIGHTNING. 4x4
NOTE: SPECIAL ORDER (DSO) UNITS WILL BE CODED WITH THE APPROPRIATE SERIES VIN CODES LISTED ABOVE.
V2379-P
Engine Type, Displacement, Cylinders, Fuel and Manufacturer

VlNPOsmON8
1FT E F25~5 S LAOOOO1

I
DISPl.ACEMENT
VlNCODE UTER aD CYUNDERS FUEL MANUFACTURER
Y 4.9 300 1-8 GASOLINE FORD
N 5.0 302 V-8 GASOUNE FORD
H 5.8 351 V-8 GASOLINE FORD
R 5.8HP 351 V-8 GASOUNE FORD
C 5.9 359 1-8 DIESEL CUMMINS
G 7.5 480 V-8 GASOUNE FORD
M 7.3 445 V-8 DIESEL NAVISTAR
F 7.3 01 TURBO 445 V-8 DIESEL NAVISTAR

ALL RIGHTS RESERVED
VEHICLE IDENTIFICATION NUMBER (Continued)
Check Digit for All Vehicles Production Sequence Number
VIN POSITION 9
~
YIN POSmONS 12 THROUGH 17
1FT E F25 H 5 S LI AOOOO1 I

I
1FT E F25 H AOOO01
SEQUENCE NUMBER
A ‫סס‬oo1 - A 99,999
V2381-P B ‫סס‬oo1 - B 99,999
AND SO ON.
Vehicle Model Year

YIN 'OSmON 10
1FT E F25 H 5~L A00001

Y2384-P
f VEHICLE CERTIFICATION LABEL (VC LABEL)

YIN CODE YEAR CODES
S 1995
T.............•............................................................... 1996 Vehicle Type Codes
V 1997 The vehicle data appears on the certification label on
W 1998 the second and third lines following the identification
x 1999 number.
Y 2000
• The code set (two numbers, or several letters, or a
1..••••....................................................................... 2001
number and letter) above COLOR identify the
2 ...................•.........................................................2002 exterior paint color (two sets of codes designate a
two-tone).
V2382-P • The digits under WB designate the wheelbase in
inches.
Assembly Plant Codes • The letter and three digits under TYPE-GVW
designate the truck model within a series and the
VIN POSmON l ' gross vehicle weight rating.
1FT E F25 H 5 S~ AOOOO1 • The letters and / or numeral under BODY designate
the interior trim, seat and body type.
I • The transmission installed in the vehicle is identified
YIN VEHICLE ASSEMBLV PLANT under TRANS by an alphabetical code.
CODE NAME AND : LOCATlON
C ONTARIO TRUCK: OAKVILLE, ONTARIO • A letter and a number or two numbers under AXLE
E KENTUCKY TRUCK: JEFFERSON, KENTUCKY identify the rear axle ratio.
H LORAIN: LORAIN, OHIO • The letters and / or numerals under TAPE designate
K KANSAS CI1Y: CLAYCOMO, MISSOURI the external body side tape stripe code.
L MICHIGAN TRUCK: WAYNE, MICHIGAN
N NORFOLK: NORFOLK, VIRGINIA • The spring usage codes for the vehicle are identified
P TWIN CITIES: ST. PAUL, MINNESOTA under SPRING.
U LOUISVILLE: LOUISVILLE, KENTUCKY A two-digit number is stamped above DSO to identify
V KENTUCKY TRUCK: JEFFERSON, KENTUCKY the district which ordered the vehicle. If the vehicle is
built to special order (Domestic Special Order, Foreign
V2383-P Special Order, Limited Production Option, or other
special order), the complete order number will also
appear above DSO. The following charts illustrate the
vehicle codes.

ALL RIGHTS RESERVED
VEHICLE CERTIFICATION LABEL (VC LABEL)

CODES (Continued)
Exterior Paint Color Codes

DATE: GVWR:
FRONTGAWR: REARGAWR:
WITH WITH
TIRES nRES
RIMS RIMS
AT PSI COLD AT PSI COLD
THIS VEHIClE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR
VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF
MANUFACTURE SHOWN ABOVE.
VIN: I
TYPE:
.
I
YC
11111111111111111111I
I
EXTERIOR PAINT COLORS DSO
we
133
I TVPEGVW I BODY I TRANS
E
I AXLE I TAPE
B
I SPRING
2K21
F251 AJ4 342
F-SERIES LABEL SHOWN
BRONCO EXTERIOR PAINT COLOR CODES F-160-250-360 AND F-SUPER DUTY EXTERIOR PAINT COLOR CODES
• CODE COLOR CODE COLOR
YC RAVEN BLACK YC RAVEN BLACK
CB DESERT COFFEE CC MC MEDIUM SILVER METALLIC
XC TUCSON BRONZE CC MS DARK GREY METALUC
WA CRIMSON YV COLONIAL WHITE
LA ROYAL BLUE CC METAWC OW DARK MOCHA METALLIC
NA DEEP FOREST GREEN CC METALLIC PB JEWEL GREEN METALUC
PL TOBAGO GREEN CC K3 BRILLIANT BLUE CC METALLIC
GC IRIS CC METAUIC EG ELECTRIC RED CC METALUC
KE BRILLIANT BLUE CC METAWC OJ MEDIUM MOCHA METALLIC
EG ELECTRIC RED CC METAWC YO OXFORD WHITE
yy COLONIAL WHITE WM UGHTOPALCC
WM LIGHT OPAL CC PC REEF BLUE METALLIC
UA EBONYCC GC IRIS CC METALliC
YO OXFORD WHITE PL TOBAGO GREEN CC
FIBERGLASS ROOF COLORS KH DARK BLUE METALUC
A BLACK NA DEEP FOREST GREEN CC METALLIC
B MEDIUM ROYAL BLUE METALLIC UA BLACKCC
C CURRANT RED WH CRIMSONCC
W OXFORD WHITE FC SUNRISE RED CC
LA ROYAL BLUE CC METALLIC
KG MEDIUM BLUE METALUC
KN MIDNIGHT BLUE CC METALLIC
WA CRIMSON
XD TUCSON BRONZE CC
CB DESERT COPPER CC
NOTE - TWO SETS OF CODES INDICATES TWO-TONE PAINT
CODE: CC • CLEAR COAT OVER COLOR PAINT
Y2868-M

ALL RIGHTS RESERVED
CODES (Continued)
Gross Vehicle Weight Code

DATE: GVWR:
FRONT GAWR: REAR GAWR:
WITH WITH
TIRES TIRES
RIMS RIMS
THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR

VIN: I
TYPE:
YC
1111111111111 ~I I ~I I I I I I I ~ 111111111111111 ~IIII~IIIIIII~ III
WB I TYPE GVW I BODY I TRANS I AXLE I TAPE I SPRING
~
133 AK4 E 342 B 2K21
IF2511 }--l
~
SERIES GVWR
~ GVWR WHEELBASE SERIES GVWR GVWR WHEELBASE
SERIES CODE CODE (LB.) (IN.) SERIES CODE CODE (LB.) (IN.)
BRONCO F-250 (4x4) X26 8 8800 155
U150 U15 2 6050 105 F26 8 8600 133
U15 4 6300 105 F-350 (4x2) F35 2 10,000 133
F37 4 8800 133
F-150-250-350 F37 8 10,000 137, 161
F37 9 11,000 137, 161
F-150 (4x2) F15 6 6100 117 W35 2 9200 168
F15 3 5250 117 W35 3 10,000 168
F15 4 5450 133 X35 1 10,000 155
F15 5 6250 133
F15 1 5000 117 F-350 (4x4) F36 1 9000 133
F15 2 5450 117 F38 2 8800 133
F15 7 5150 117 F38 4 11,000 137, 161
X15 1 6050 139 F38 1 16,000 137
X15 2 6250 155 W36 1 9200 168
F-150 (4x4) F14 1 6100 117 F-SUPER DUTY (4x2) F47 8 15,000 185
F14 2 6250 133 CHASSIS CAB F47 7 15,000 137, 161
X14 3 6250 139 F-SUPER DUTY F53 1 16,000 178,203
X14 1 6250 155 MOTORHOME 1 17,000 178, 190
F-250 (4x2) F25 1 6600 133 STRIPPED CHASSIS 208,228
LIGHT DUTY F53 0 15,200 178
F-250 (4x2) F25 7 8600 133
HEAVY DUTY X25 9 8800 155
Y2669-M
DAVE
Drivetrain INC.
July 1994 - 2014
ALL RIGHTS RESERVED
00-01·10 Identification Codes 00-01·10

CODES (Continued)
Body Codes
MFD. BY FORD MOTOR co. IN U.S.A.

DATE: GVWR:
WITH WITH
nRES TIRES
RIMS RIMS

~~
I
lYPE:
YC
'111111111111111111111
133 F251 AJ4 E 342 B 2K21
F-sERIES LABEL SHOWN
. - - - - - - - - - - - - - -.....: A ~-...
JI41
................
SEATS, F-SERES
~ CAB/BACK OF CAB.+F-SERlES ONLY
CODE FABRIC TYPE REGULAR SPEClFlCAnON
A VINYL BENCH 4 STYLESIDE PICKUP
B KNIT VINYL BENCH 8 CHASSIS CAB
X STRIPPED CHASSIS (MEXICO)
C KNrrVINYL BENCH
M STYLESIDE PICKUP - SUPER CAB
o BODYCLOTH FLIGHT BENCH D STYLESIDE PICKUP - CREW CAB
F CLOTH CAPTAINS CHAIR 3 FLARESIDE
G BODYCLOTH BENCH C FLARESIDE - SUPER CAB
P CLOTH BUCKET TRIM COLOR, BRONCO AND F-SERiES
J CLOTH 40/20/40 CODE COLOR
SEATS, BRONCO J GRANITE
CODE FABRIC TYPE R RUBY
S VINYL BUCKET .. K MEDIUM MOCHA
Y CLOTH CAPTAINS CHAIR 6 MEDIUM OPAL
W CLOTH CAPTAINS CHAIR V LAPIS
X LEATHER CAPTAINS CHAIR
U CLOTHNINYL SPLIT BENCH Y2388-P
DAVE GRAHAM
July 1994
ALL RIGHTS RESERVED

CODES (Continued)
Transmission Codes

DATE: GVWR:
FRONT GAWR: REAR
GAWR: WITH WITH
TIRES TIRES
RIMS RIMS

VIN: I
n:lllllllllllllllllln~
I TYPE GVW I I I I I SPRING
WB
133 F251
BODY
AJ4 Cfl
TRANS AXLE
342
TAPE
B 2K21
r-- I F-SERIES LABEL SHOWN
CODE I DESCRIPTION
+ F-150-250-350, F-SUPER DUTY CHASSIS CAB
BRONCO G AUTOMATIC - C6
M I MANUAL - 5-SPEED OVERDRIVE (M50D) (MAZDA) U AUTOMATIC 4R70W
E I AUTOMATIC - E40D E AUTOMATIC - E40D
C MANUAL - 5-SPEED CLOSE RATIO (Z-F)
M MANUAL - 5-SPEED OVERDRIVE (M50D) (MAZDA)
W MANUAL - 5-SPEED H.D. OVERDRIVE
(M50D-HD) (Z-F)
CY2390-N
DAVE
Drivetrain INC.
- 2014
July 1994
ALL RIGHTS RESERVED

CODES (Continued)
Axle Codes

DATE: GVWR:
WITH WITH
TIRES TIRES
RIMS RIMS

VIN: I
TYPE:
YC
I I I I I~ 111111111111111111111111111111111111111111111111111111111111II~I~IIIII
W8 I TYPE GVW I BODY I TRANS I AXLE I TApE I SPRING
133 F251 AK4 E ~ E 2K21
I
1251 2 I
!
REAR AXLE CODES FRONT AXLE CODE
~
CODE CAPACITY (LBS.) RATIO t----.;;c..;;.02..;..D..;;..E_~_--.;D~E...;.S..;..CR;....I.;...PT.;..;.IO..;;..N I
12 3800 2.73 1. " LIMITED-SLIP ,
18 3800 3.08
17 3800 3.31
19 3800 3.55
H7 3800 3.31 LS
H8 3800 3.08 LS
H9 3800 3.55 LS
25 3800 4.10
29 5300 3.55
B5 5300 4.10 LS
89 5300 3.55 LS
35 6250 4.10
39 6250 3.55
C5 6250 4.10 LS
C9 6250 3.55 LS
45 7400 4.10
49 7400 3.55
D5 7400 4.10 LS
65 8250 4.10
69 8250 3.55
F5 8250 4.10 LS
F8 FOM only
72 11,000 4.63
73 11,000 5.13
W5 8250 4.00
LS =LIMITED SLIP
Y2671·K
DAVE GRAHAM
1995 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain July 1994 INC. - 2014
ALL RIGHTS RESERVED
CODES (Continued)
Tape Stripe Codes

DATE: GVWR:
WITH WITH
TIRES nRES
RIMS RIMS

VEHIClE SAFETY STANDARDS IN EFFECT ON THE DATE OF
YIN:
n:11111111111111111111
EXTERIOR PAINT COLORS Dsa
we I TYPE GVW I BODY I TRANS AXLE I SPRING
133 F261 AJ4 E 342 2K21
F·SERIES LABEL SHOWN
BRONCO EXTERNAL TUTONE BODY TAPE STRIPE CODES F·150-25Q-350, ALL TUTONES STYLESiDE TAPE
CODE TAPE STRIPE CODE TAPE STRIPE
A BLACK/SILVER A BLACK/SILVER
B OK SHAD BLUE/SILVER B MEO ROYAL BlUE/SILVER
0 CABERNET/SilVER 0 VERMILLION/SILVER
E (SCARlEnlSllVER E ELECTRIC CURRANT RED/SILVER
G LT OPAL/SILVER G lTOPAl/SILVER
J OK TOURMALINE/SILVER J OK TOURMALINE/SllVER
l LAPIS/SILVER L LAPIS/SilVER
p MED CALYPSO/OXFORD WHITE M AQUA/OXFORD WHITE
R IRIS/SILVER N REEF BLUE/SILVER
T SANTE FE/COLONIAL WHITE P MED CALYPSO/OXFORD WHITE
R IRIS/SILVER
F·150-250-350 FlARESIDE LO-UNE TAPE T LT SANTE FE/COLONIAL WHITE
CODE U MED PALOMINO/COLONIAL WHITE
TAPE STRIPE
C Y MOCHA/DARK MOCHA
HOT PlNK/lAVENDER
H HOT PINK/SllVER
K SEA GREENIlAVENOER
0 MED AQUA/DK AQUA
SPORT PACKAGE
7 SILVER
Y2872-M

ALL RIGHTS RESERVED

CODES (Continued)
Suspension Spring Codes

DATE: GVWR:
FRONTGAWR: REAR GAWR:
WITH WITH
TIRES TIRES
RIMS RIMS

VIN: I
TYPE:
YC
~I~II~"~IIIIIIIIIHIIII
133 F251 AJ4 E 342 B
l4ill
I
AUX./OPT. USAGE CODE (FRONT)
I 2 IK I2 I I I
I
FRON~ SPRING CODE I

BRONCO AUX./OPT. UJAGE CODE (REAR)
CODE PART NUMBER
J F4TA-5310-JA REAR iPRING CODE
K F4TA-5310-KA BRONCO
1
2
F4TA-5310-RA
F4TA-5310-SA
F-150-250-350, F-SUPER DUTY
I
CODE
D I
PART NUMBER
F4TA-5560-DB
F-150-250-350, F-SUPER. DUTY
I
CODe PART NUMBER CODE PART NUMBER
H F4TA-5310-HA G F5TA-5560-UA
J F4TA-5310-JA H F4TA-5560-MA
K F4TA-5310-KA J F4TA-5560-SA
M F4TA-5310-MA K F4TA-5560-XB
N F4TA-5310-NA L F4TA-5560-LB
B F4TA-5310-PA N F4TA-5560-NB
R F1TA-5310-ANA P F4TA-5560-PB
S F1TA-5310-APA I F4TA-5560-JB
T F1TA-5310-ARA A F4TA-ETA-5560-SA
U F4TA-5310-UA A E4TA-SA
5 F1TA-5310-AHA F F4TA-5560-TA
6 F1TA-5310-AJA 9 F2TA-5560-VB
7 F1TA-5310-AKA 8 F4TA-5A975-AB/BB (LH/RH)
8 F1TA-5310-AMA
9 F1TA-5310-ALA
1 F4TA-5310-RA
L F4TA-5310-LA
2 F4TA-5310-SA
3 F4TA-5310-TA
4 F4TA-5310-VA
X F4TA-5310-XA
Y F4TA-5310-YB
p F3TA-5310-SA
V2673-K

ALL RIGHTS RESERVED
CODES (Continued)
District, Special Order and Wheelbase Codes

DATE: GVWR:
WITH WITH
nRES llRES
RIMS RIMS
~N: I
TYPE:
YC
111111111111111111111
21
DSO
_ _-I.r-otWstB-;1 TYPE GVW I BODY I TRANS I AXLE I TAPE I SPRING
... 133 I F251 AJ4 E 342 8 2K21
F-SERlES LABEL SHOWN
DSO - FSO - PTO (DOMESTIC, FOREIGN AND SPECIAL ORDER)

THE DSO SPACE WILL SHOW A TWO-DIGIT CODE NUMBER OF THE DISTRICT
WHEELBASE (INCHES) WHICH ORDERED THE UNIT (SEE CHART BELOW). THIS CODE WILL APPEAR ON
ALL UNITS - DOMESTIC OR EXPORT. IF UNIT IS BUILT ON A OSO, FSO, PTO
I~~-----I
(SPECIAL ORDERS), THE COMPLETE ORDER NUMBER IS UNDER THE DSO
SPACER AFTER THE DISTRICT CODE NUMBER.
F-SUPER
DUTY
117 137 CODE DETROIT FORD OF CANADA
133 166 161 11 80STON MERCURY REGIONS FORD REGIONS
137 161 158 13 NEW YORK
139 188 178 16 PHIlADELPHIA A1 CENTRAL B1 CENTRAL
208 21 ATLANTA A2 EASTERN B2 EASTERN
23 MEMPHIS A3 ATLANTIC 83 ATLANTIC
24 ORLANDO A4 MIDWESTERN 84 MIDWESTERN
27 WASHINGTON AS WESTERN 86 WESTERN
41 CHICAGO A7 PACIFIC B7 PACIFIC
44 PITTSBURGH AS GREAT LAKES 88 GREAT LAKES
47 CINCINNATI 11 EXPORT 11 EXPORT
48 DETROIT
52 DALLAS
63 KANSASCrTY
58 DENVER
58 'TWIN CITIES
71 LOS ANGELES
72 SAN FRANCISCO
74 SEATTLE
83 GOVERNMENT
84 HOME OFFICE RESERVE (HOR)
86 AMERICAN RED CROSS
86 RECREATION VEHICLE POOL
87 BODY COMPANY
89 TRANSPORTATION SERVICES
9A EXPORT
Y2392-N
ALL RIGHTS RESERVED
00-03·1 Maintenance and Lubrication 00-03·1
SECTION 00-03 Maintenance and Lubrication

VEHICLE APPLICATION ...•••...•.....••••••.•...•..•••••.......••••00-03-1 MAINTENANCE (Cont'd.)
DESCRIPTION When Stopping for Fuel ••...••••••••••••••••.•••••••••••.••••00-o3-5
Diesel Rating - Diesel Engine ••...•..•...•.....•••••...•...•OO-03-3 While Operating the Vehlcle •••••••••••••••••••....•••••••••00-o3-5
Engine Oil Viscosity ....•..•.••.•.•••...•..•...••....•••••...••.••.00-03-3 Regularly Scheduled Maintenance
Gasoline Octane Rating - Gas Engines••••••••••.••••••00-o3-3 Intervals•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••00-03-4
Scheduled Maintenance - Emissions ••••••.•..•..••••••00-03-2 Severe-Duty Schedule ••••••.••••••••••••••.•••••••••••••••••••00-03-10
Vehicle Emission Control Information (VECI) Severe-Duty Schedule, Motorhome
Decal ...•....••.•...•.....•••........•.•.••.••••....•••.••.•.....•••••00-03-1 Vehicles ..••••.•••••.••••..••••••.•••••••••••••......••••••••••••••00-03-16
MAINTENANCE What Maintenance Schedule Do You
Maintenance Information •••••••...•....••••••.••••••••••••....•00-03-4 Follow? ••••••.••.••••••••••••••••••••.•••.••••••••..•••••••••••••••.•00-03-4
Normal Schedule .....•..•..••••..•....••.••.•.•......•••..•••..••••00-03-5 LUBRICATION
Owner Maintenance Checks ..••••.....•.••••••..•.••..•••••..00-03-5 Lubrication Points .••••••.•••.••••••••.••••.••••••.•••••..•••••••00-03-21
At Least Monthly••••.•.•.....•••..•••..•...•..•.•....•••....•••..00-03-5 Service Points _ Chassls ••.••••••.••••••••••••••••••••••••••00-o3-26
At Least Once a Year .•••••.......•••••....•...•••••........•..00-03-5 Service Points - Engine Compartment •••••••••..••••00-03-22
At Least Twice a Year.•.••........••••••.....•..••••••...•.••••00-o3-5 SPECIFICATIONS ••..••••••.••••••••••••••••••.•••••.•••••••••...••••00-03-28
VEHICLE APPLICATION
F-150, F-250, F-350, F-Super Duty and Bronco
DESCRIPTION
Vehicle Emission Control Information (VECI)

Decal
Vacuum hoses on the engine have a color stripe to aid
in hose routing checks. The stripe will usually be the
same color as on the Vehicle Emission Control
Information (VECI) decal, but the correct vacuum hose
routing must be verified by using the correct
component connections shown on the VECI decal.
1995 F-150, F-250, F-350, Bronco, F..Super Duty Powertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
DESCRIPTION (Continued)
Typical VEel Decal
FORD MOTOR COM NY VACUUM HOSE ROUTING
IMPORTANT VEHICLE FORMATION +

THIS VEHICLE IS QUIPPED WITH EEC IV MFI STEMS. IDLE SPEEDS AND
:~~~~~>r-N~~~ ARE NOT ADJUSTABLE. SEE HOP MANUAL FOR ADDITIONAL
ADJUST IGNITION TIMING WITH THE TRANSMISSION IN NEUTRAL

PARKING BRAKE SET AND THE WHEELS BLOCKED. ENGINE MUST 'BE
AT NORMAL OPERATING TEMPERATURE.
(nTURN OFF ENGINE.
(2) DISCONNECT THE IN-LINE SPOUT CONNECTOR ( -DO- OR -Oil ).
(3) RE-START PREVIOUSLY WARMED-UP ENGINE.
(4) ADJUST IGNITION TIMING TO 10· BTDC.
(5) TURN OFF ENGINE AND RESTORE ELECTRICAL CONNECTION.
FIRING ORDER - 15426318
THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS APPLICABLE TO 1995
MODEL YEAR NEW LIGHT-DUTY TRUCKS. COMPLIANCE PEMONSTRATED ANp
peSIGNep ~OR ~RINCIPAL USE BELOW 4000 FEET FOR NEW VEHICLE
CO~PL~A~ E A OVE 4000 FEET. SEE SERVICE PUBLICATIONS.
+ ~."'CU
TY~CALVE~CLEE~
CONTROL INFORMA11ON DECAL
(UNDER 8500 GVW) A10418-F
Part Part
Item Number Description Item Number Description
1 - Adjustment Procedure Notes 4 - Spark Plug Gap
2 - Ignition Timing Specification Specification
3 - Engine Vacuum Hose Routing 5 - Engine Type
(Typical)
(Continued)
Scheduled Maintenance - Emissions CAUTION: To assure the durability of the vehicle

The required maintenance schedules appearing on the and its emission control systems, it is necessary
following pages list the items required to maintain the that scheduled maintenance be performed at the
vehicle emission systems at intervals determined by designated Intervals.
the federal government (Environmental Protection Ford recommends the use of genuine Ford
Agency). replacement parts. The maintenance,
Refer to the appropriate sections of the Powertrain replacement, or repair of the Emissions Control
1
Control/Emissions Diagnosis Manual for the devices and systems (the cost of which is not
maintenance procedures, which are related to the covered by warranty) may be performed by any
items listed in the maintenance schedule. Use these automotive repair establishment or Individual and
procedures to perform the required emission system may use other than Ford service parts for such
maintenance items listed in the maintenance maintenance or repair. If other than Ford or
schedules. Motorcraft parts or Ford authorized
remanufactured parts are used for maintenance
replacements or the service of components
affecting emissions control, the owner should
assure himself that such parts are warranted by
their manufacturer to be equivalent to genuine
Ford Motor Company parts in performance and
durability. Please consult the warranty booklet
for complete warranty information.
1 Can be purchased as a separate item.


ALL RIGHTS RESERVED
NOTE: The PCV valve is a critical emissions Engine Oil Viscosity

component. The dealer will replace the valve at no WARNING: CONTINUOUS CONTACT WITH USED
cost at 60,000 miles (96,000 kilometers) (except MOTOR OIL HAS CAUSED SKIN CANCER IN
Canada and California vehicles). LABORATORY MICE. PROTECT YOUR SKIN BY
For vehicles with 7.5L engines, the dealer will replace WASHING WITH SOAP AND WATER.
the PCV valve at no cost at 60,000 miles (96,000 NOTE: All compact truck engines are filled with SAE
kilometers) (except Canada vehicles). 5W-30 oil at the factory.
Any modification of the emission control systems
could create liability under federal law (U.S.) if made Gasoline Engines (4.9L, 5.0L, 5.8L, 7.5L)
prior to the first sale and registration, and under the To choose the correct viscosity oil, temperatures in
laws of some states if made thereafter. Further, which the vehicle will be driven must be considered.
federal law prohibits vehicle manufacturers, dealers The use of SAE 5W-30 oil is preferred in all climate
and other persons engaged in the business of conditions. The use of SAE 10W-30 is acceptable in
repairing, servicing, selling, leasing, or trading motor moderate to hot climates.
vehicles as well as fleet operations from knowingly
removing or rendering an emission control system
inoperative after sale and delivery to an ultimate
purchaser. In Canada, modifications of the emission
control system could create liability under applicable
federal or provincial laws.
NOTE: For vehicles equipped with optional dual fuel
tanks, do not allow one fuel tank to run dry before
switching tanks. Running the fuel tank dry will cause J@
air to enter the fuel system, thereby stalling the engine.
Longer than normal cranking time may be required to
I-I
restart the engine. If you run out of fuel while the

vehicle is in motion, immediately turn on the hazard
warning flashers.
Ford recommends using Motorcraft oil or an equivalent

Gasoline Octane Rating - Gas Engines oil meeting Ford specification ESE-M2C 153-E and
CERTIFIED by the American Petroleum Institute
The vehicles are designed to use fuel with an octane
FOR GASOLINE ENGINES.
rating of at least 87.
Use only engine oils displaying the American
Petroleum Institute CERTIFICATION MARK on the
front of the container.
87
I
_~ THE API CERTlFlCA1l0N MARK
MINIMUM OCTANE RATING
(R - M) 2 METHOD
.-.
Y5336-A
MoIDICIBft
Fuel with a lower octane rating can cause persistent .....~1OW-30
and heavy knocking, which can damage the engine. ~
i;
lllUMlf ..... lI
LOOK FOR THIS
Diesel Rating - Diesel Engine CERTIFICATION MARK
The 7.3L diesel engine is designed to use number 1-D Y5745-A
or 2-D diesel fuel only. At temperatures below -7°C
(20°F), number 1-D or winter blend number 2-D fuel is Diesel Engine 7.3L
recommended.
For normal or severe service, use Motorcraft oil or an
NOTE: Do not add gasoline, gasohol, alcohol or equivalent oil conforming to Ford specification
cetane improvers to diesel fuel. Damage to the fuel ESR-M2C 171-8 or API categories CG-4 / SG, SH or
injection system may result. CE / SG, SH (if former is not available). Do not use oils
labeled with only one of the following category
designations, SG, SH, CE or CG-4, as they could
cause engine damage.

ALL RIGHTS RESERVED
vv-vv-.... 1.lgll I ..VI Igl I " V g l IU ~U"'I l"g"I"1 I
Engine oils with improved fuel economy properties Whenever a high tension ignition wire is removed from
(energy conserving) are currently available. If you use a spark plug, the distributor cap, or the coil to perform
an energy conserving oil, be sure it meets the a maintenance operation, Silicone Dielectric
recommended Ford Specification, API service Compound WA-10, D7AZ-19A331-A or equivalent
categories and SAE viscosity grades listed in the meeting Ford specification ESE-M 1C171-A must be
Specifications chart. Some energy conserving oils do applied to the boot before reconnection. Using a small"
not meet the requirements necessary for your diesel clean screwdriver, apply a thin layer of Silicone
engine. Dielectric Compound on the entire interior surface of
the boot.
As a safety precaution, before starting the engine to
SAE VISCOSITY GRADES perform maintenance, make sure the transmission
I I I selector is in park (automatic transmission) or neutral
15W-40 Preferred (manual transmission), the parking brake set and the
wheels blocked.
I I I
Preferred 10W-30
I I I What Maintenance Schedule Do You Follow?

5W-30
I I I Schedules are based on how vehicle is driven.
FO -20 -10 0 10 20 30 40 50 60 70 80 90 100
I I
Co I i I
I
I
I
-30 -25 -20 -15 -10- -5 0
I
I I I
I I I H I
I I
I
5 10 15 20 25 30 35 40
I
I I
I I
EXPECTED TEMPERATURE RANGE Regularly Scheduled Maintenance Intervals
Follow the Normal Schedule for most normal everyday
Y5746-A driving conditions.
NOTE: The use of SAE 30 oil is preferred when Follow the Severe-Duty Schedule if driving habits
ambient temperatures are above 0 °C (32 °F). When FREQUENTLY include one or more of the following
temperatures are expected to be below O°C (32°F), conditions:
SAE 10W-30 oil should be used. Only when using • Towing a trailer or carrying a heavy load.
10W-30 oils, API category CD / SG, SH is acceptable,
although CF-4/SH, SG or CE/SG, SH is preferred. • Operating in severe dust conditions.
The use of correct oil viscosities (thickness) for diesel • Extensive idling such as door-to-door delivery
engines is important for satisfactory operation service.
(especially in cold weather). Determine which oil • Snowplowing.
viscosity best suits the temperature range that is
expected to be encountered for the next service • Off-road operation.
interval. • Short trips of less than 10 miles (16 km) when
outside temperatures remain below -18°C (O°F).
NOTE: Idling the engine for extended periods will
MAINTENANCE accumulate more hours of use on the vehicle than
actually indicated by the mileage odometer.
Consequently, the odometer reading can be often
Maintenance Information misleading when determining the right time to change
The maintenance recommendations are included in engine oil and filter.
this section for reference. The emission systems If the vehicle is used in a manner which allows it to
scheduled maintenance services are shown in bold remain stationary while the engine is running for long
type. Be sure to perform all maintenance services. periods (door-to-door delivery, power / utility company
Maintenance service adjustments must conform to trucks, or similar duty), then Ford recommends
specifications contained in the Powertrain increasing frequency of oil and filter changes to an
Control/Emissions Diagnosis Manual 2 , to those listed interval equivalent to 200 ENGINE HOURS of use.
in the Truck Performance Specifications issue of the Since most vehicles are not equipped with
Technical Service Bulletin or shown on the Vehicle hourmeters, it may be necessary for you to
Emission Control Information Decal which is located on approximate your idle time and plan oil / filter changes
or near the engine, or the emission systems may accordingly.
become inoperative.


ALL RIGHTS RESERVED
MAINTENANCE (Continued)
Owner Maintenance Checks • Flush complete underside of vehicle.

Listed below are vehicle maintenance checks and • Inspect underbody components for damage.
inspections that should be performed by the owner or
• Check exhaust system for leaks, damage or loose
qualified service technician at the indicated intervals. parts and remove any foreign material trapped by
The Owner Guide contains supporting specifications shielding.
and service information.
• Check parking brake system.
Any adverse conditions should be brought to the
attention of the dealer or qualified service technician • Check headlamp alignment.
as soon as possible. • Check seat and shoulder belt webbing, buckles and
The owner maintenance checks are generally not release mechanisms.
covered by warranties. • Inspect seat back latches for proper operation.
When Stopping for Fuel • Check air pressure in spare tire.
• Check the engine oil level. At Least Once a Year
• Check the windshield washer fluid level. • Lubricate door hinges, checks, and hood hinges.
• Look for low or underinflated tires. • Lubricate door, hood and deck / liftgate locks, and
• Check tow hitch security if towing a trailer or latches, including swing-away spare tire carrier
vehicle. latch and striker.
While Operating the Vehicle • Lubricate door rubber weatherstrips.
• Inspect and lubricate automatic transmission cable
• Note any changes in the sound of the exhaust or and controls.
any smell of exhaust fumes in the vehicle.
• Clean battery and terminals, check electrolyte level
• Check for vibration in the steering wheel. Notice any on low maintenance (auxiliary and replacement)
increased steering effort or looseness in the batteries.
steering wheel, or change in its straight ahead
position. • Check manual transmission, transfer case, front
and rear axle fluid levels.
• Notice if the vehicle constantly turns slightly or
··pulls" to one side when traveling on smooth, level
road.
• When stopping, listen and check for strange Normal Schedule
sounds, pulling to one side, increased brake pedal
travel or hard-to-push brake pedal. NOTE: Items for emission control service are shown in
bold type. For items marked with number in
• If any slipping or changes in the operation of the parentheses, see footnotes at end of this schedule.
transmission occurs, check the transmission fluid
level. NOTE: Kilometer intervals are rounded off.
• Check automatic transmission PARK function. 5,000 Miles (8,000 km)
• Check parking brake. • Change engine oil and replace oil filter.
At Least Monthly • Rotate tires and adjust air pressure. (1) (2)
• Check and lubricate clutch release lever (7.5L and
• Check and adjust tire pressure (cold). 7.3L diesel).
• Check coolant level in the coolant recovery
• Check clutch reservoir fluid level.
reservoir.
• Inspect and lubricate automatic transmission shift
• Check operation of lights, horn, turn signals, linkage.
windshield wipers and washers, and hazard
warning flasher. • Lubricate steering linkage suspension, driveshaft
U-joint, if equipped with grease fittings, and lubricate
• Check for fluid leaks by inspecting the surface slip-yoke (if equipped).
beneath the vehicle for oil, coolant, or other fluid
drips. Clean water from the air conditioning system • NOTE: It is normal for a certain amount of moisture
is normal. and staining to be present around the muffler
seams. The presence of soot, light surface rust or
At Least Twice a Year moisture does not indicate a faulty muffler.
• Check power steering reservoir fluid level. Inspect exhaust system for leaks, damage or loose
parts. Remove any foreign material trapped by
• Check fluid level in clutch master cylinder.
exhaust system shielding.
• Check radiator, heater and air-conditioning hoses
for leaks or damage. 10,000 Miles (16,000 km)
• Check for worn tires. • Change engine oil and replace oil filter.
• Clean body and door drain holes.

ALL RIGHTS RESERVED
00-03-6 Maintenance and Lubrication 00-03-6
15,000 Miles (24,000 km) • NOTE: It is normal for a certain amount of moisture
and staining to be present around the muffler
• Change engine oil and replace oil filter. seams. The presence of soot, light surface rust or
• Inspect engine cooling system, hoses, and moisture does not indicate a faulty muffler.
clamps; check coolant strength every 15,000 Inspect exhaust system for leaks, damage or loose
miles (24,000 km) or 12 months. parts. Remove any foreign material trapped by
• Rotate tires and adjust air pressure. (1) (2) exhaust system shielding.
• Check clutch reservoir fluid level. 30,000 Miles (48,000 km)
• Lubricate transfer case shift lever pivot bolt and • Change engine oil and replace 011 filter.
control rod connecting pins (4x4).
• Replace spark plugs (gasoline engines only).
linkage. • Change engine coolant every 30,000 miles
(48,000 km) or 36 months and add FW-15 (7.3L
• Lubricate steering linkage suspension, driveshaft diesel only).
slip-yoke (if equipped). • Inspect engine cooling system, hoses, and
clamps; check coolant strength every 15,000
• Inspect disc brake system; lubricate caliper slide miles (24,000 km) or 12 months.
rails.
• Replace air cleaner filter every 30,000 miles
• Inspect drum brake systems, hoses and lines. (48,000 km) or 30 months. If operating in dusty
• NOTE: It is normal for a certain amount of moisture conditions, follow severe-duty maintenance
and staining to be present around the muffler schedule.
seams. The presence of soot, light surface rust or • Replace the air cleaner filter when the
moisture does not indicate a faulty muffler. restriction gauge Is in the red zone (7.3L diesel
Inspect exhaust system for leaks, damage or loose only).
parts. Remove any foreign material trapped by • Replace crankcase emission air filter. If
exhaust system shielding. operating in dusty conditions, follow
• Inspect parking brake fluid level (F-Super Duty). severe-duty maintenance schedule (4.9L, 5.0L
• Replace fuel filer every 15,000 miles (24,000 km)
manual transmission, and 7.5L only).
or when the filter restriction lamp is illuminated (7.3L • Change automatic transmission fluid (except C6 and
diesel only). E40D transmissions).
• Change fuel filter (recommended but not required for • Lubricate transfer case shift lever pivot bolt and
California certified vehicles). control rod connecting pins (4x4).
• Check spring U-bolt torque (F-Super Duty). • Inspect disc brake system; lubricate caliper slide
rails.
• Replace fuel filter, frame-mounted.
• Change fuel filter (recommended but not required for • Inspect drum brake systems, hoses and lines.
California certified vehicles). • Inspect and lubricate front wheel bearings.
• Replace oil filter every 15,000 miles (24,000 km) or • Inspect parking brake system for damage and
when filter restriction lamp is illuminated. operation.
20,000 Miles (32,000 km) • Inspect parking brake fluid level (F-Super Duty).
• Lubricate throttle kickdown or TV lever ball studs.
• Change engine oil and replace 011 filter.
• Lubricate front axle RH axle shaft slip-yoke (4x4).
7.3L diesel). • Inspect and lubricate spindle needle bearings (4x4).
25,000 Miles (40,000 km) • Inspect and lubricate hub locks (4x4).
• Check spring U-bolt torque (F-Super Duty).
• Change engine oil and replace 011 filter.
• Replace fuel filter every 15,000 miles (24,'000 km)
• Rotate tires and adjust air pressure. (1) (2) or when the filter restriction lamp is illuminated (7.3L
• Check clutch reservoir fluid level. diesel only).
• Inspect and lubricate automatic transmission shift • Change fuel filter (recommended but not required for
linkage. . California certified vehicles).
• Lubricate steering linkage suspension, driveshaft 35,000 Miles (56,000 km)
slip-yoke (if equipped). • Change engine oil and replace oil filter.
• Rotate tires and adjust air pressure. (1) (2)
7.3L diesel).

ALL RIGHTS RESERVED
• Check clutch reservoir fluid level. 55,000 Miles (88,000 km)

• Inspect and lubricate automatic transmission shift • Change engine oil and replace 011 filter.
linkage.
• Lubricate steering linkage suspension, driveshaft
U-joint, if equipped with grease fittings, and lubricate • Inspect and lubricate automatic transmission shift
slip-y~ke (if equipped). linkage.
• NOTE: It is normal for a certain amount of moisture • Lubricate steering linkage suspension, driveshaft
and staining to be present around the muffler U-joint, if equipped with grease fittings, and lubricate
seams. The presence of soot, light surface rust or slip-yoke (if equipped).
moisture does not indicate a faulty muffler. • NOTE: It is normal for a certain amount of moisture
Inspect exhaust system for leaks, damage or loose and staining to be present around the muffler
parts. Remove any foreign material trapped by seams. The presence of soot, light surface rust or
exhaust system shielding. moisture does not indicate a faulty muffler.
Inspect exhaust system for leaks, damage or loose
40,000 Miles (64,000 km) parts. Remove any foreign material trapped by
• Change engine 011 and replace 011 filter. exhaust system shielding.
45,000 Miles (72,000 km) 60,000 Miles (96,000 km)
• Change engine oil and replace oil filter. • Change engine oil and replace 011 filter.
• Inspect engine cooling system, hoses, and • Inspect engine cooling system, hoses, and
clamps; check coolant strength every clamps; check coolant strength every
15,000 miles (24,000 km) or 12 months. 15,000 miles (24,000 km) or 12 months.
• Rotate tires and adjust air pressure. (1) (2) • Change engine coolant every 30,000 miles
• Check clutch reservoir fluid level. diesel only).
• lubricate transfer case shift lever pivot bolt and • Replace spark plugs (gasoline engines only).
• Inspect and lubricate automatic transmission shift (48,000 km) or 30 months. If operating In dusty
linkage. conditions, follow severe-duty maintenance
• Lubricate steering linkage suspension, driveshaft schedule.
• Replace the air cleaner filter when the
slip-yoke (if equipped). restriction gauge Is In the red zone (7.3L diesel
• Change fuel filter (recommended but not required for only).
California certified vehicles).
• Replace crankcase emission air filter. If
• Replace fuel filter every 15,000 miles (24,000 km) operating In dusty conditions, follow
or when the filter restriction lamp is illuminated (7.3L severe-duty maintenance schedule (4.9L, 5.0L
diesel only). manual transmission and 7.5L only).
• Inspect disc brake system; lubricate caliper slide • Replace PCV valve. (3)
rails.
• Check thermactor hoses and clamps
• Inspect drum brake systems, hoses and lines. (recommended but not required).
• NOTE: It is normal for a certain amount of moisture • Inspect accessory drive belt condition.
and staining to be present around the muffler • Lubricate transfer case shift lever pivot bolt and
seams. The presence of soot, light surface rust or control rod connecting pins (4x4).
moisture does not indicate a faulty muffler.
• Change automatic transmission fluid (except C6 and
Inspect exhaust system for leaks, damage or loose E40D transmissions).
exhaust system shielding. • Replace fuel filter every 15,000 miles (24,000 km)
or when the filter restriction lamp is illuminated (7.3L
• Inspect parking brake fluid level (F-Super Duty). diesel only).
• Check spring U-bolt torque (F-Super Duty). • Change fuel filter (recommended but not required for
50,000 Miles (80,000 km) California certified vehicles).
• Inspect disc brake system; lubricate caliper slide
• Change engine 011 and replace 011 filter. rails.
• Change engine coolant Initially at 50,000 miles
(80,000 km) or 48 months. Thereafter, change • Inspect drum brake systems, hoses and lines.
engine coolant every 30,000 miles (48,000 • Inspect and lubricate front wheel bearings.
km) 36 months (gasoline engine.s only). • Inspect parking brake system for damage and
• Check and lubricate clutch release lever (7.5L and operation.
,7.3L diesel).
1995 F-150, F-250, F-350, Bronco~ F-Super Duty Powertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
• Inspect parking brake fluid level (F-Super Duty). • Inspect and lubricate automatic transmission shift
linkage.
• Inspect and lubricate spindle needle bearings (4x4). • Check clutch reservoir fluid level.
• Inspect and lubricate hub locks (4x4). • Lubricate transfer case shift lever pivot bolt and
• Change transfer case oil (4x4).
• Inspect parking brake fluid level (F-Super Duty).
• Lubricate front axle RH axle shaft slip-yoke (4x4).
• Change manual transmission oil.
80,000 Miles (128,000 km)
65,000 Miles (104,000 km) • Change engine oli and replace oil filter.
• Change engine coolant every 30,000 miles
• Change engine oil and replace oil filter. (48,000 km) or every 36 months (gasoline
• Rotate tires and adjust air pressure. (1) (2) engines only).
• Lubricate steering linkage suspension, driveshaft • Check and lubricate clutch release lever (7.5L and
U-joint, if equipped with grease fittings, and lubricate 7.3L diesel).
slip-yoke (if equipped). 85,000 Miles (136,000 km)
• NOTE: It is normal for a certain amount of moisture
and staining to be present around the muffler • Change engine oil and replace oil filter.
seams. The presence Of soot, light surface rust or • Rotate tires and adjust air pressure. (1) (2)
Inspect exhaust system for leaks, damage or loose U-joint, if equipped with grease fittings, and lubricate
parts. Remove any foreign material trapped by slip-yoke (if equipped).
• Inspect and lubricate automatic transmission shift and staining to be present around the muffler
linkage. seams. The presence of soot, light surface rust or
• Check clutch reservoir fluid level. moisture does not indicate a faulty muffler.
• Check and lubricate clutch release lever (7.5L and Inspect exhaust system for leaks, damage or loose
7.3L diesel). parts. Remove any foreign material trapped by
70,000 Miles (112,000 km) • Inspect and lubricate automatic transmission shift
• Change engine oil and replace oil filter. linkage.
75,000 Miles (121,000 km) • Check clutch reservoir fluid level.

90,000 Miles (144,000 km)
• Change engine oil and replace oil filter.
• Inspect engine cooling system, hoses, and • Change engine oil and replace oil filter.
clamps; check coolant strength every • Replace spark plugs (gasoline engines only).
15,000 miles (24,000 km) or 12 months.
• Inspect engine cooling system, hoses, and
• Rotate tires and adjust air pressure. (1) (2) clamps; check coolant strength every
• Lubricate steering linkage suspension, driveshaft 15,000 miles (24,000 km) or 12 months.
U-joint, if equipped with grease fittings, and lubricate • Change engine coolant every 30,000 miles
slip-yoke (if equipped). (48,000 km) or 36 months, and add FW-15
• NOTE: It is normal for a certain amount of moisture (7.3L diesel only).
and staining to be present around the muffler • Replace air cleaner filter every 30,000 miles
·seams. The presence of soot, light surface rust or (48,000 km) or 30 months. If operating in dusty
moisture does not indicate a faulty muffler. conditions, follow severe-duty maintenance
Inspect exhaust system for leaks, damage or loose schedule.
parts. Remove any foreign material trapped by • Replace the air cleaner filter when the
exhaust system shielding. restriction gauge is in the red zone (7.3L diesel
• Inspect disc brake system; lubricate caliper slide only).
rails. • Replace crankcase emission air filter. If
• Inspect drum brake systems, hoses and lines. operating in dusty conditions, follow
severe-duty maintenance schedule (4.9L, 5.0L
• Change fuel filter (recommended but not required for manual transmission and 7.5L onJy).
• Inspect accessory drive belt condition.
• Replace fuel filter every 15,000 miles (24,000 km)
or when the filter restriction lamp is illuminated (7.3L • Replace fuel filter every 15,000 miles (24,000 km)
diesel only). or when the filter restriction lamp is illuminated (7.3L
diesel only).
1995 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain,. Drivetrain JuJV·i1 Q4,
~ .,~;,; .. ~«/. '
ALL RIGHTS RESERVED
• Change fuel filter (recommended but not required for • Replace fuel filter every 15,000 miles (24,000 km)
California certified vehicles). or when the filter restriction lamp is illuminated (7.3L
diesel only).
• Inspect parking brake system for damage and
operation. • Change fuel filter (recommended but not required for
rails. • NOTE: It is normal for a certain amount of moisture
• Inspect drum brake systems, hoses and lines.
• Inspect and lubricate front wheel bearings. moisture does not indicate a faulty muffler.
• Lubricate throttle kickdown or TV lever ball studs. Inspect exhaust system for leaks, damage or loose
• Inspect and lubricate hub locks (4x4). parts. Remove any foreign material trapped by
• Inspect and lubricate spindle needle bearings (4x4).
• Lubricate transfer case shift lever pivot bolt and rails.
• Inspect drum brake systems, hoses and lines.
• Change automatic transmission fluid (except C6 and
E40D transmissions). • Inspect and lubricate automatic transmission shift
linkage.
• Inspect parking brake fluid level (F-Super Duty).
• Lubricate transfer case shift lever pivot bolt and
• Lubricate front axle RH axle shaft slip-yoke (4x4). control rod connecting pins (4x4).
95,000 Miles (152,000 km) • Inspect parking brake fluid level (F-Super Duty).
• Change engine oil and replace oil filter. • Check spring U-bolt torque (F-Super Duty).
• Rotate tires and adjust air pressure. (1) (2) 110,000 Miles (176,000 km)
• Lubricate steering linkage suspension, driveshaft • Change engine oil and replace 011 filter.
slip-yoke (if equipped). • Change engine coolant every 30,000 miles
(48,000 km) or every 36 months (gasoline
• NOTE: It is normal for a certain amount of moisture engines only).
seams. The presence of soot, light surface rust or • Check and lubricate clutch release lever (7.5L and
moisture does not indicate a faulty muffler. 7.3L diesel).
Inspect exhaust system for leaks, damage or loose 115,000 Miles (184,000 km)
exhaust system shielding. • Change engine oil and replace 011 filter.
• Inspect and lubricate automatic transmission shift • Rotate tires and adjust air pressure. (1) (2)
linkage. • Lubricate steering linkage suspension, driveshaft
• Check clutch reservoir fluid level. U-joint, if equipped with grease fittings, and lubricate
slip-yoke (if equipped).
7.3L diesel). • NOTE: It is normal for a certain amount of moisture
100,000 Miles (160,000 km) seams. The presence of soot, light surface rust or
• All rear axle lube quantities must be replaced every parts. Remove any foreign material trapped by
100,000 miles (160,000 km) or if the axle has been exhaust system shielding.
submerged in water. Otherwise, the lube should
not be checked or changed unless a leak is • Inspect and lubricate automatic transmission shift
suspected or repair required. linkage.
105,000 Miles (168,000 km) • Check clutch reservoir fluid level.
120,000 Miles (192,000 km)
• Inspect engine cooling system, hoses, and • Change engine oil and replace oil filter.
clamps; check coolant strength every • Replace spark plugs (gasoline engines only).
• Inspect accessory drive belt condition.
• Lubricate steering linkage suspension, driveshaft clamps; check coolant strength every
U-joint, if equipped with grease fittings, and lubricate 15,000 miles (24,000 km) or 12 months.
slip-yoke (if equipped).

ALL RIGHTS RESERVED
00-03·10 Maintenance and Lubrication 00-03-10
• Replace air cleaner filter every 30,000 miles For F-Super Duty Rear Axles Only:
(48,000 km) or 30 months. If operating in dusty The lube change interval should be shortened to
conditions, follow severe-duty maintenance 4,800 km (3,000 miles) or 3 months, whichever
schedule. occurs first, under the following conditions:
(48,000 km) or 36 months and add FW·15 (7.3L - Extended trailer tow operation above 21 ° C
diesel only). (70°F).
• Replace the air filter when the restriction - Ambient and wide open throttle for extended
gauge is in the red zone (7.3L diesel only). periods above 72 km/h (45 mph).
• Replace crankcase emission air filter. If The 3,000 miles (4,800 km) change interval may be
operating in dusty conditions, follow waived if the axle has been filled with Ford approved
severe-duty maintenance schedule (4.9L, 5.0L 75W-140 synthetic gear lubricant meeting
manual transmission and 7.5L only). WSL-M2C192-A, Ford specification F1TZ-19580-B.
• Replace PCV valve.
• Check thermactor hoses and clamps.
• Inspect parking brake. system for damage and Severe-Duty Schedule
operation. NOTE: Items for emission control service are shown in
• Inspect disc brake system; lubricate caliper slide bold type.
rails. For items marked with a number in parentheses, see
• Inspect drum brake systems, hoses and lines. footnotes at the end of this schedule.
• Inspect and lubricate front wheel bearings. NOTE: The Severe-Duty Schedule provides
maintenance intervals for replacing air cleaner filter if
• Lubricate throttle kickdown or TV lever ball studs. vehicle is driven in severe dust conditions. However,
• Inspect and lubricate hub locks (4x4). some driving conditions may require even more
• Inspect and lubricate spindle needle bearings (4x4). frequent air cleaner replacement intervals than those
shown.
control rod connecting pins (4x4). NOTE: Kilometer intervals are rounded off.
• Change automatic transmission fluid (except C6 and 3,000 Miles (5,000 km)
E40D transmissions). • Change engine oil and replace oil filter.
• Inspect parking brake fluid level (F-Super Duty). • Check and lubricate clutch release lever (7.5L and
• Check spring U-bolt torque (F-Super Duty). 7.3L diesel).
• Replace manual transmission oil. 6,000 Miles (10,000 km)
• Replace transfer case oil (4x4). • Change engine oil and replace oil filter.
• Lubricate front axle RH axle shaft slip-yoke (4x4). • Rotate tires and adjust air pressure. (3) (5) (6)
• Change fuel filter (recommended but not required for • Check clutch reservoir fluid level.
• Replace fuel filter every 15,000 miles (24,000 km) linkage.
or when the filter restriction lamp is illuminated (7.3L
diesel only). • NOTE: It is normal for a certain amount of moisture
(1) Wheellugnuts must be retightened to proper torque moisture does not indicate a faulty muffler.
specifications at 500 miles / 800 km of new vehicle
operation (100 miles/ 160 km and 500 miles/800 km for Inspect exhaust system for leaks, damage or loose
vehicles equipped with dual rear wheels or equipped for parts. Remove any foreign material trapped by
snowplowing). Proper torque specifications are exhaust shielding.
provided in this section. Also retighten to proper torque
specification at 500 miles /800 km after (1) any wheel
change or (2) any other time the wheellugnuts have U-joint, if equipped with grease fittings, and lubricate
been loosened. slip-yoke (if equipped). (2)
(2) On dual rear wheel vehicles, rotate the front tires side to 9,000 Miles (15,000 km)
side without disturbing the rear tires.
(3) At 60,000 miles (96,000 km) dealer will replace the PCV
valve at no cost except on Canada and California 12,000 Miles (20,000 km)
vehicles.

ALL RIGHTS RESERVED
• Inspect and lubricate automatic transmission shift • NOTE: It is normal for a certain amount of moisture
linkage. and staining to be present around the muffler
• NOTE: It is normal for a certain amount of moisture seams. The presence of soot, light surface rust or
and staining to be present around the muffler moisture does not indicate a faulty muffler.
seams. The presence of soot, light surface rust or Inspect exhaust system for leaks, damage or loose
moisture does not indicate a faulty muffler. parts. Remove any foreign material trapped by
Inspect exhaust system for leaks, damage or loose exhaust shielding.
parts. Remove any foreign material trapped by • Lubricate steering linkage suspension, driveshaft
exhaust shielding. U-joint, if equipped with grease fittings, and lubricate
slip-yoke (if equipped). (2)
U-joint, if equipped with grease fittings, and lubricate • Lubricate throttle kickdown or TV lever ball studs.
27,000 Miles (45,000 km)
15,000 Miles (25,000 km)
30,000 Miles (50,000 km)
clamps; check coolant strength every • Change engine oil and replace oil filter.
15,000 miles (25,000 km) or 12 months. • Replace air cleaner filter every 30,000 miles
• Rotate tires and adjust air pressure. (3) (5) (6) (50,000 km) or 30 months. (1)
• Lubricate transfer case shift lever pivot bolt and • Replace the air cleaner filter when the
control rod connecting pins (4x4). restriction gauge is in the red zone (7.3L diesel
only). (1)
• Inspect disc brake system and lubricate caliper
slide rails. (2) • Change engine coolant every 30,000 miles
(50,000 km) or 36 months and add FW·15 (7.3L
• Inspect drum brake systems, lines and hoses. diesel only).
• Change fuel filter (recommended but not required for
clamps; check coolant strength every
18,000 Miles (30,000 km) 15,000 miles (25,000 km) or 12 months.
• Change engine oil and replace oil filter. • Replace spark plugs (gasoline engines only).
• Check clutch reservoir fluid level. • Replace crankcase emission air filter (4.9L,
5.0L manual transmission and 7.5L only). (1)
linkage. • Inspect and lubricate automatic transmission shift
linkage.
and staining to be present around the muffler • NOTE: It is normal for a certain amount of moisture
seams. The presence of soot, light surface rust or and staining to be present around the muffler
moisture does not indicate a faulty muffler. seams. The presence of soot, light surface rust or
parts. Remove any foreign material trapped by Inspect exhaust system for leaks, damage or loose
exhaust shielding. parts. Remove any foreign material trapped by
exhaust shielding.
• Inspect parking brake fluid (F-Super Duty).
• Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate
U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped). (2)
• Check and lubricate clutch release lever (7.5L and control rod connecting pins (4x4).
7 .3L diesel).
21,000 Miles (35,000 km) slide rails. (2)
• Change engine oil and replace oil filter. • Inspect drum brake systems, lines and hoses.
• Change automatic transmission fluid. • Change fuel filter (recommended but not required for
24,000 miles (40,000 km)
• Change fuel filter every 15,000 miles (25,000 km)
• Change engine oil and replace oil filter. (7.3L diesel only).
• Rotate tires and adjust air pressure. (3) (5) (6) • Inspect and lubricate front wheel bearings. (2)
• Inspect and lubricate automatic transmission shift • Inspect parking brake system for damage and
linkage. operation.
1995 F-150. F-250. F-350. Bronco, F-Super Duty Powertrain. Drivetrain July 1994

ALL RIGHTS RESERVED
• Change manual transmission oil. • Lubricate transfer case shift lever pivot bolt and
• Lubricate front axle RH axle shaft slip-yoke (4x4). control rod connecting pins (4x4).
• Inspect and lubricate spindle needle bearings (4x4). • Inspect disc brake system and lubricate caliper
slide rails. (2)
• Inspect and lubricate hub locks (4x4).
• Inspect drum brake systems, lines and hoses.
33,000 Miles (55,000 km) • Change fuel filter (recommended but not required for
• Change engine oil and replace oil filter. California certified vehicles).
• Rotate tires and adjust air pressure. (3) (5) (6) • Change fuel filter every 15,000 miles (25,000 km)
(7 .3L diesel only).
7.3L diesel). 48,000 Miles (80,000 km)
• Inspect parking brake fluid (F-Super Duty). • Change engine oil and replace oil filter.
• Check spring U-bolt torque (F-Super Duty). • Change engine coolant initially at 48,000 miles
36,000 Miles (60,000 km) (80,000 km) or 48 months. Thereafter, change
engine coolant every 30,000 miles (50,000
• Change engine oil and replace oil filter. km) or 36 months (gasoline engines only).
• Check clutch reservoir fluid level. • Check clutch reservoir fluid level.
• Inspect and lubricate automatic transmission shift • Inspect and lubricate automatic transmission shift
linkage. linkage.
• NOTE: It is normal for a certain amount of moisture • NOTE: It is normal for a certain amount of moisture
and staining to be present around the muffler and staining to be present around the muffler
seams. The presence of soot, light surface rust or seams. The presence of soot, light surface rust or
moisture does not indicate a faulty muffler. moisture does not indicate a faulty muffler.
Inspect exhaust system for leaks damage or loose Inspect exhaust system for leaks, damage or loose
parts. Remove any foreign material trapped by parts. Remove any foreign material trapped by
exhaust shielding. exhaust shielding.
• Lubricate steering linkage suspension, driveshaft • Lubricate steering linkage suspension, driveshaft
U-joint, if equipped with grease fittings, and lubricate U-joint, if equipped with grease fittings, and lubricate
slip-yoke (if equipped). (2) slip-yoke (if equipped). (2)
39,000 Miles (65,000 km) • Lubricate throttle kickdown or TV lever ball studs.
• Check and lubricate clutch release lever (7 .5L and
• Change engine oil and replace oil filter. 7.3L diesel).
42,000 Miles (70,000 km) • Inspect parking brake fluid (F-Super Duty).
• Change engine oil and replace oil filter. • Check spring U-bolt torque (F-Super Duty).
• Change automatic transmission fluid. 51,000 Miles (85,000 km)
• Rotate tires and adjust air pressure. (3) (5) (6) • Change engine oil and replace oil filter.
• Check clutch reservoir fluid level. • Rotate tires and adjust air pressure. (3) (5) (6)
linkage. 54,000 Miles (90,000 km)
• NOTE: It is normal for a certain amount of moisture • Change engine oil and replace oil filter.
and staining to be present around the muffler • Check clutch reservoir fluid level.
moisture does not indicate a faulty muffler. • Inspect and lubricate automatic transmission shift
linkage.
parts. Remove any foreign material trapped by • NOTE: It is normal for a certain amount of moisture
exhaust shielding. and staining to be present around the muffler
• Lubricate steering linkage suspension, driveshaft moisture does not indicate a faulty muffler.
slip-yoke (if equipped). (2) Inspect exhaust system for leaks, damage or loose
45,000 Miles (75,000 km) exhaust shielding.

ALL RIGHTS RESERVED
00-03·13 Maintenance and Lubrication 00·03·13
• Lubricate steering linkage suspension, driveshaft • Change transfer case oil (4x4).
U~joint, if equipped with grease fittings, and lubricate
• Change manual transmission oil.
• Change rear axle lube (F-Super Duty only). (4)
57,000 Miles (95,000 km)
63,000 Miles (105,000 km)
60,000 Miles (100,000 km)
• Inspect engine cooling system, hoses, and • Change automatic transmission fluid.
clamps; check coolant strength every • Inspect parking brake fluid (F-Super Duty).
• Check spring Lt'Dt It torque (F ·Supe f l.Juty J
(50,000 km) or 36 months and add FW·15 (7.3L 66,000 Miles (110,000 km)
diesel only).
(50,000 km) or 30 months. (1) • Check clutch reservoir fluid level.
• Replace the air cleaner filter when the • Inspect and lubricate automatic transmission shift
restriction gauge is in the red zone (7.3L diesel linkage.
only). (1) • NOTE: It is normal for a certain amount of moisture
• Replace crankcase emission air filter. and staining to be present around the muffler
• Replace PCV valve. (7) moisture does not indicate a faulty muffler.
• Check thermactor hoses and clamps Inspect exhaust system for leaks, damage or loose
(recommended but not required). parts. Remove any foreign material trapped by
• Inspect accessory drive belts. exhaust shielding.
• Replace spark plugs (gasoline engines only). • Lubricate steering linkage suspension, driveshaft
• Rotate tires and adjust air pressure. (3) (5) (6) slip-yoke (if equipped). (2)
69,000 Miles (115,000 km)
linkage. • Change engine oil and replace oil filter.
• NOTE: It is normal for a certain amount of moisture • Rotate tires and adjust air pressure. (3) (5) (6)
72,000 Miles (120,000 km)
moisture does not indicate a faulty muffler. • Change engine oil and replace oil filter.
Inspect exhaust system for leaks, damage or loose • Check clutch reservoir fluid level.
exhaust shielding. • Inspect and lubricate automatic transmission shift
linkage.
U-joint, if equipped with grease fittings, and lubricate • NOTE: It is normal for a certain amount of moisture
slip-yoke (if equipped). (2) and staining to be present around the muffler
• Lubricate transfer case shift lever pivot bolt and moisture does not indicate a faulty muffler.
• Inspect disc brake system and lubricate caliper parts. Remove any foreign material trapped by
slide rails. (2) exhaust shielding.
• Inspect drum brake systems, lines and hoses. • Lubricate steering linkage suspension, driveshaft
• Change fuel filter (recommended but not required for U-joint, if equipped with grease fittings, and lubricate
California certified vehicles). slip-yoke (if equipped). (2)
• Change fuel filter every 15,000 miles (25,000 km) • Lubricate throttle kickdown or TV lever ball studs.
(7 .3L diesel only). 75,000 Miles (125,000 km)
• Inspect and lubricate front wheel bearings (2).
operation. • Inspect engine cooling system, hoses and
• Lubricate front axle RH axle sha~ slip-yoke (4x4). 15,000 miles (25,000 km) or 12 months.
• Inspect and lubricate spindle needle bearings (4x4). • Lubricate transfer case shift lever pivot bolt and
• Inspect and lubricate hub locks (4x4). control rod connecting pins (4x4).

ALL RIGHTS RESERVED
• Inspect disc brake system and lubricate caliper 90,000 Miles (150,000 km)
slide rails. (2)
• Inspect drum brake linings, lines and hoses.
• Change fuel filter (recommended but not required for (50,000 km) or 30 months. (1)
• Replace the air cleaner filter when the
• Change fuel filer every 15,000 miles (25,000 km) restriction gauge is in the red zone (7.3L diesel
(7.3L diesel only). only). (1)
78,000 Miles (130,000 km) • Change engine coolant every 30,000 miles
• Change engine oil and replace oil filter. diesel only).
• Change engine coolant every 30,000 miles • Inspect engine cooling system, hoses and
(50,000 km) or 36 months (gasoline engines clamps; check coolant strength every
only). 15,000 miles (25,000 km) or 12 months.
• Rotate tires and adjust air pressure. (3) (5) (6) • Inspect accessory drive belts.
• Check clutch reservoir fluid level. • Replace spark plugs (gasoline engines only).
• Inspect and lubricate automatic transmission shift • Replace crankcase emission air filter 4.9L,
linkage. 5.0L manual transmission and 7.5L only). (1)
• NOTE: It is normal for a certain amount of moisture • Check clutch reservoir fluid level.
seams. The presence of soot, light surface rust or • Inspect and lubricate automatic transmission shift
moisture does not indicate a faulty muffler. linkage.
Inspect exhaust system for leaks, damage or loose • NOTE: It is normal for a certain amount of moisture
parts. Remove any foreign material trapped by and staining to be present around the muffler
exhaust shielding. seams. The presence of soot, light surface rust or
U-joint, if equipped with grease fittings, and lubricate Inspect exhaust system for leaks, damage or loose
slip-yoke (if equipped). (2) parts. Remove any foreign material trapped by
exhaust shielding.
• Check and lubricate clutch release lever (7 .5L and
7.3L diesel). • Lubricate steering linkage suspension, driveshaft
• Inspect parking brake fluid (F-Super Duty). slip-yoke (if equipped). (2)
• Check spring U-bolt torque (F-Super Duty). • Inspect disc brake system and lubricate caliper
81,000 Miles (135,000 km) slide rails. (2)
• Inspect drum brake systems, lines and hoses.
• Change engine 011 and replace oil filter.
84,000 Miles (140,000 km) California certified vehicles).
• Change engine oil and replace oil filter. • Inspect and lubricate front wheel bearings. (2)
• Check clutch reservoir fluid level. • Inspect parking brake system for damage and
operation.
• Change automatic transmission fluid.
• Inspect and lubricate automatic transmission shift • Change manual transmission oil.
linkage. • Lubricate transfer case shift lever pivot bolt and
and staining to be present around the muffler • Lubricate front axle RH axle shaft slip-yoke (4x4).
seams. The presence of soot, light surface rust or • Inspect and lubricate spindle needle bearings (4x4).
• Change rear axle lube (F-Super Duty only). (4)
parts. Remove any foreign material trapped by • Inspect and lubricate hub locks (4x4).
exhaust shielding. 93,000 Miles (155,000 km)
U-joint, if equipped with grease fittings, and lubricate • Change engine oil and replace oil filter.
slip-yoke (if equipped). (2) • Check and lubricate clutch release lever (7.5L and
7.3L diesel).
87,000 Miles (145,000 km)
• Inspect parking brake fluid (F-Super Duty).
• Rotate tires and adjust air pressure. (3) (5) (6)

ALL RIGHTS RESERVED
96,000 Miles (160,000 km) 108,000 Miles (180,000 km)

• Change engine oil and replace oil filter. • Change engine oil and replace oil filter.
• Rotate tires and adjust air pressure. (3) (5) (6) • Change engine coolant every 30,000 miles
(50,000 km) or 36 months (gasoline engines
only).
linkage. • Check clutch reservoir fluid level.
• NOTE: It is normal for a certain amount of moisture • Inspect and lubricate automatic transmission shift
and staining to be present around the muffler linkage.
seams. The presence of soot, light surface rust or • NOTE: It is normal for a certain amount of moisture
moisture does not indicate a faulty muffler. and staining to be present around the muffler
Inspect exhaust system for leaks, damage or loose seams. The presence of soot, light surface rust or
parts. Remove any foreign material trapped by moisture does not indicate a faulty muffler.
exhaust shielding. Inspect exhaust system for leaks, damage or loose
• Lubricate steering linkage suspension, driveshaft parts. Remove any foreign material trapped by
U-joint, if equipped with grease fittings, and lubricate exhaust shielding.
slip-yoke (if equipped). (2) • Lubricate steering linkage suspension, driveshaft
• Lubricate throttle kick-down or TV lever ball studs. U-joint, if equipped with grease fittings, and lubricate
99,000 Miles (165,000 km) • Check and lubricate clutch release lever (7.5L and
• Replace rear axle lube. (4) • Inspect parking brake fluid (F-Super Duty).
102,000 Miles (170,000 km)
111,000 Miles (185,000 km)
• Check clutch reservoir fluid level. • Change engine oil and replace oil filter.
• Inspect and lubricate automatic transmission shift 114,000 Miles (190,000 km)
linkage.
and staining to be present around the muffler • Rotate tires and adjust air pressure. (3) (5) (6)
seams. The presence of soot, light surface rust or • Check clutch reservoir fluid level.
moisture does not indicate a faulty muffler. • Inspect and lubricate automatic transmission shift
Inspect exhaust system for leaks, damage or loose linkage.
parts. Remove any foreign material trapped by • NOTE: It is normal for a certain amount of moisture
exhaust shielding. and staining to be present around the muffler
• Lubricate steering linkage suspension, driveshaft seams. The presence of soot, light surface rust or
U-joint, if equipped with grease fittings, and lubricate moisture does not indicate a faulty muffler.
slip-yoke (if equipped). (2) Inspect exhaust system for leaks, damage or loose
exhaust shielding.
• Change engine oil and replace oil filter. • Lubricate steering linkage suspension, driveshaft
• Inspect engine cooling system, hoses, and U-joint, if equipped with grease fittings, and lubricate
clamps; check coolant strength every slip-yoke (if equipped). (2)
117,000 Miles (195,000 km)
• Change automatic transmission fluid. • Change engine oil and replace oil filter.
• Lubricate transfer case shift lever pivot bolt and 120,000 Miles (200,000 km)
slide rails. (2) • Inspect engine cooling system, hoses, and
• Inspect drum brake systems, lines and hoses. 15,000 miles (25,000 km) or 12 months.
• Change fuel filter (recommended but not required for • Replace air cleaner filter every 30,000 miles
California certified vehicles). (50,000 km) or 30 months. (1)
• Change fuel filter every 15,000 miles (25,000 km) • Replace the air cleaner filter when the
(7.3L diesel only). restriction gauge is in the red zone (7.3L diesel
only). (1)

ALL RIGHTS RESERVED

(3) City delivery vehicles and other unique applications that
require constant turning may need more frequent tire
diesel only). rotation. Tire rotation interval may be based on the tire
• Replace spark plugs (gasoline engines only). wear.
• Replace crankcase emission air filter (4.9L, (4) F-SUPER DUTY APPLICATIONS must change axle lube
5.0L manual transmission and 7.5L only). (1) every 30,000 miles (48,000 km) unless synthetic oil is
used. Super Duty vehicles are NOT equipped with
• Replace PCV valve. synthetic oil from the factory.
• Check thermactor hoses and clamps (5) Wheellugnuts must be retightened to proper torque
(recommended but not req~ired). specifications at 500 miles (800km) of new vehicle
operation 100 miles (160 km) and 500 miles (800 km)
• Inspect accessory drive belts. for vehicles equipped with dual rear wheels or equipped
• Check clutch reservoir fluid level. for snowplowing). Proper torque specifications are
• Inspect and lubricate automatic transmission shift specification at 500 miles (800 km) after (1) any wheel
linkage. change or (2) any other time the wheellugnuts have
been loosened.
and staining to be present around the muffler (6) On dual rear wheel vehicles, rotate the front tires
seams. The presence of soot, light surface rust or side-to-side without disturbing the rear tires.
moisture does not indicate a faulty muffler. (7) At 60,000 miles (96,000 km) dealer will replace the PCV
valve at no cost except on Canada and California
vehicles.
exhaust shielding.
For F-Super Duty Rear Axles Only:
• Lubricate steering linkage suspension, driveshaft The lube change interval should be shortened to
3,000 miles (4,800 km) or 3 months, whichever
occurs first, under the following conditions:
Extended trailer tow operation above 21 ° C
• Lubricate transfer case shift lever pivot bolt and (70°F).
Ambient and wide open throttle for extended
• Inspect disc brake system and lubricate caliper periods above 72 km/h (45 mph).
slide rails. (2)
The 3,000-mile (4,800-km) change interval may be
• Inspect drum brake systems, lines and hoses. waived if the axle has been filled with Ford approved
• Change fuel filter (recommended but not required for 75W-140 synthetic gear lubricant meeting
California certified vehicles). WSL-M2C192-A, Ford specification F1TZ-19580-B.
• Change fuel filter every 15,000 miles (25,000 km)
(7.3L diesel only).
• Inspect and lubricate front wheel bearings. (2) Severe-Duty Schedule, Motorhome Vehicles
• Inspect parking brake system for damage and NOTE: Items.for emission control service are shown in
operations. bold type.
• Lubricate front axle RH axle shaft slip-yoke (4x4). For items marked with a number in parentheses, see
• Inspect and lubricate spindle needle bearings (4x4). footnotes at the end of this schedule.
• Inspect and lubricate hub locks (4x4). NOTE: The Severe-Duty Schedule provides
• Change transfer case oil (4x4). maintenance intervals for replacing air cleaner filter if
vehicle is driven in severe dust conditions. However,
• Change rear axle lube (F-Super Duty only). (4) some driving conditions may require even more
• Change manual transmission oil. frequent air cleaner replacement intervals than those
shown.
(1) Extremely dusty conditions will require more frequent NOTE: Kilometer intervals are rounded off.
replacement of your air filter. Check your air filter at 3,000 Miles (5,000 km)
3,000 miles (5,000 km). If it is dirty, replace it and then
keep replacing it at the same interval every 3,000 miles • Change engine oil and replace oil filter.
(5,000 km). If it is not dirty, check it again at
6,000 miles (10,000 km) and again at 9,000 miles 6,000 Miles (10,000 km)
(14,500 km) until the required maintenance interval is
established. Do not go beyond 30,000 miles • Change engine oil and replace oil filter.
(48,000 km).
(2) If the vehicle is operated "off road" in water that is
deeper than the hubs (1/2 wheel height), then these • Inspect and lubricate automatic transmission shift
items must be serviced daily. linkage.
(Continued)

ALL RIGHTS RESERVED
• NOTE: It is normal for a certain amount of moisture 21,000 Miles (35,000 km)
seams. The presence of soot, light surface rust or • Change engine oil and replace oil filter.
moisture does not indicate a faulty muffler. • Change automatic transmission fluid.
exhaust shielding. • Change engine oil and replace oil filter.
• Lubricate steering linkage suspension, driveshaft • Rotate tires and adjust air pressure. (3) (5) (6)
U-joint if equipped with grease fittings and lubricate • Inspect and lubricate automatic transmission shift
slip-yoke (if equipped). (2) linkage.
12,000 Miles (20,000 km) moisture does not indicate a faulty muffler.
• Change engine oil and replace oil filter. Inspect exhaust system for leaks, damage or loose
• Inspect and lubricate automatic transmission shift exhaust shielding.
linkage.
• NOTE: It is normal for a certain amount of moisture U-joint, if equipped with grease fittings, and lubricate
and staining to be present around the muffler slip-yoke (if equipped). (2)
moisture does not indicate a faulty muffler. • Lubricate throttle kickdown or TV lever ball studs.
exhaust shielding.
• Replace air cleaner filter every 48,000 km
U-joint if equipped with grease fittings and lubricate
(30,000 miles) or 30 months. (1)
slip-yoke (if equipped). (2) • Inspect engine cooling system, hoses, and
15,000 Miles (25,000 km) 15,000 miles (25,000 km) or 12 months.
• Change engine oil and replace oil filter. • Replace spark plugs.
• Inspect engine cooling system, hoses, and • Replace crankcase emission air filter. (1)
15,000 miles (25,000 km) or 12 months. • Inspect and lubricate automatic transmission shift
linkage.
• Inspect disc brake system and lubricate caliper and staining to be present around the muffler
slide rails. (2) seams. The presence of soot, light surface rust or
• Change fuel filter (recommended but not required for moisture does not indicate a faulty muffler.
California certified vehicles). Inspect exhaust system for leaks, damage or loose
exhaust shielding.
• Change engine oil and replace oil filter. • Lubricate steering linkage suspension, driveshaft
• Inspect and lubricate automatic transmission shift U-joint, if equipped with grease fittings, and lubricate
linkage. slip-yoke (if equipped). (2)
• NOTE: It is normal for a certain amount of moisture • Inspect disc brake system and lubricate caliper
and staining to be present around the muffler slide rails. (2)
moisture does not indicate a faulty muffler. • Change fuel filter (recommended but not required for
parts. Remove any foreign material trapped by • Inspect and lubricate front wheel bearings. (2)
exhaust shielding. • Inspect parking brake system for damage and
operation.
U-joint, if equipped with grease fittings, and lubricate 33,000 Miles (55,000 km)

ALL RIGHTS RESERVED
• Inspect and lubricate automatic transmission shift moisture does not indicate a faulty muffler.
linkage. Inspect exhaust system for leaks, damage or loose
• NOTE: It is normal for a ce~tain amount of moisture parts. Remove any foreign material trapped by
and staining to be present around the muffler exhaust shielding.
seams. The presence of soot, light surface rust or • Lubricate steering linkage suspension, driveshaft
moisture does not indicate a faulty muffler. U-joint, if equipped with grease fittings, and lubricate
Inspect exhaust system for leaks, damage or loose slip-yoke (if equipped). (2)
parts. Remove any foreign material trapped by • Lubricate throttle kickdown or TV lever ball studs.
exhaust shielding.
51,000 Miles (85,000 km)
U-joint, if equipped with grease fittings, and lubricate • Change engine oil and replace oil filter.
39,000 Miles (65,000 km)
54,000 Miles (90,000 km)
42,000 Miles (70,000 km) • Inspect and lubricate automatic transmission shift
• Change engine oil and replace oil filter. linkage.
• Change automatic transmission fluid. • NOTE: It is normal for a certain amount of moisture
• Rotate tires and adjust air pressure. (3) (5) (6) seams. The presence of soot, light surface rust or
• Inspect and lubricate automatic transmission shift moisture does not indicate a faulty muffler.
linkage. Inspect exhaust system for leaks, damage or loose
• NOTE: It is normal for a certain amount of moisture parts. Remove any foreign material trapped by
and staining to be present around the muffler exhaust shielding.
seams. The presence of soot, light surface rust or • Lubricate steering linkage suspension, driveshaft
moisture does not indicate a faulty muffler. U-joint, if equipped with grease fittings, and lubricate
Inspect exhaust system for leaks, damage or loose slip-yoke (if equipped). (2)
parts. Remove any foreign material trapped by 57,000 Miles (95,000 km)
exhaust shielding.
• Lubricate steering linkage suspension, driveshaft • Change engine oil and replace oil filter.
U-joint, if equipped with grease fittings, and lubricate 60,000 Miles (100,000 km)
45,000 Miles (75,000 km)
• Change engine oil and replace oil filter. clamps; check coolant strength every
• Inspect engine cooling system, hoses, and 15,000 miles (25,000 km) or 12 months.
clamps; check coolant strength every • Replace air cleaner filter every 30,000 miles
15,000 miles (25,000 km) or 12 months. (50,000 km) or 30 months. (1)
• Inspect disc brake system-and lubricate caliper • Replace crankcase emission air filter. (1)
slide rails. (2)
• Replace PCV valve. (7)
• Change fuel filter (recommended but not required for • Check thermactor hoses and clamps
California certified vehicles). (recommended but not required).
48,000 Miles (80,000 km) • Inspect accessory drive belts.
• Change engine oil and replace oil filter. • Replace spark plugs.
• Change engine coolant initially at 48,000 miles • Rotate tires and adjust air pressure. (3) (5) (6)
(80,000 km) or 48 months. Thereafter, change • Inspect and lubricate automatic transmission shift
engine coolant every 30,000 miles (50,000 linkage.
km) or 36 months (gasoline engines only).
• Inspect and lubricate automatic transmission shift and staining to be present around the muffler
linkage. seams. The presence of soot, light surface rust or
exhaust shielding.

ALL RIGHTS RESERVED
• Lubricate steering linkage suspension, driveshaft· • Inspect disc brake system and lubricate caliper
U-joint, if equipped with grease fittings, and lubricate slide rails. (2)
• Inspect disc brake system and lubricate caliper California certified vehicles).
slide rails. (2)
78,000 Miles (130,000 km)
California certified vehicles). • Change engine oil and replace oil filter.
• Inspect and lubricate front wheel bearings. (2) • Rotate tires and adjust air pressure. (3) (4) (6)
• Inspect parking brake system for damage and • Inspect and lubricate automatic transmission shift
operation. linkage.
• Change automatic transmission fluid. moisture does not indicate a faulty muffler.
• Change engine oil and replace oil filter. exhaust shielding.
• Inspect and lubricate automatic transmission shift • Lubricate steering linkage suspension, driveshaft
linkage. U-joint, if equipped with grease fittings, and lubricate
and staining to be present around the muffler 81,000 Miles (135,000 km)
• Lubricate steering linkage suspension, driveshaft • Change automatic transmission fluid.
U-joint, if equipped with grease fittings, and lubricate • Inspect and lubricate automatic transmission shift
slip-yoke (if equipped). (2) linkage.
69,000 Miles (115,000 km) • Inspect exhaust system for leaks, damage or loose
• Rotate tires and adjust air pressure. (3) (5) (6) • Lubricate steering linkage suspension, driveshaft
72,000 Miles (120,000 km) slip-yoke (if equipped). (2)
• Change engine oil and replace oil filter. 87,000 Miles (145,000 km)
linkage. • Change engine oil and replace oil filter.
• NOTE: It is normal for a certain amount of moisture • Rotate tires and adjust air pressure. (3) (5) (6)
and staining to be present around the muffler 90,000 Miles (150,000 km)
Inspect exhaust system for leaks, damage or loose • Replace air cleaner filter every 30,000 miles
parts. Remove any foreign material trapped by (50,000 km) or 30 months. (1)
exhaust shielding. • Inspect engine cooling system, hoses, and
• Lubricate steering linkage suspension, driveshaft clamps; check coolant strength every
U-joint, if equipped with grease fittings, and lubricate 15,000 miles (25,000 km) or 12 months.
• Inspect accessory drive belts.
• Lubricate throttle kickdown or TV lever ball studs. • Replace spark plugs.
75,000 Miles (125,000 km) • Replace crankcase emission air filter.
• Change engine oil and replace oil filter. • Inspect and lubricate automatic transmission shift
linkage.
15,000 miles (25,000 miles) or 12 months.

ALL RIGHTS RESERVED
• NOTE: It is normal for a certain amount of moisture 102,000 Miles (175,000 km)
seams. The presence of soot, light surface rust or • Change engine oil and replace oil filter.
moisture does not indicate a faulty muffler. • Inspect engine cooling system, hoses, and
Inspect exhaust system for leaks, damage or loose clamps; check coolant strength every
parts. Remove any foreign material trapped by 15,000 miles (25,000 km) or 12 months.
exhaust shielding. • Rotate tires and adjust air pressure. (3) (5) (6)
• Lubricate steering linkage suspension, driveshaft • Inspect disc brake system and lubricate caliper
U-joint, if equipped with grease fittings, and lubricate slide rails. (2)
• Inspect disc brake system and lubricate caliper California certified vehicles).
slide rails. (2)
108,000 Miles (180,000 km)
California certified vehicles). • Change engine oil and replace oil filter.
• Inspect and lubricate front wheel bearings. (2) • Change engine coolant every 30,000 miles
(50,000 km) or 36 months (gasoline engines
operation. only).
93,000 Miles (155,000 km) linkage.
• Change engine oil and replace oil filter. • NOTE: It is normal for a certain amount of moisture
96,000 Miles (160,000 km)
• Change engine oil and replace oil filter. moisture does not indicate a faulty muffler.
• Rotate tires and adjust air pressure. (3) (4) (6) Inspect exhaust system for leaks, damage or loose
• Inspect and lubricate automatic transmission shift exhaust shielding.
linkage.
• NOTE: It is normal for a certain amount of moisture U-joint, if equipped with grease fittings, and lubricate
and staining to be present around the muffler slip-yoke (if equipped). (2)
moisture does not indicate a faulty muffler. 111,000 Miles (185,000 km)
Inspect exhaust system for leaks, damage or loose • Change engine oil and replace oil filter.
exhaust shielding. 114,000 Mile (190,000 km)
• Lubricate steering linkage suspension, driveshaft • Change engine oil and replace oil filter.
slip-yoke (if equipped). (2) . • Rotate tires and adjust air pressure. (3) (5) (6)
• Lubricate throttle kickdown or TV lever ball studs. • Inspect and lubricate automatic transmission shift
linkage.
• Change engine oil and replace oil filter. and staining to be present around the muffler
• Replace rear axle lube. (4) moisture does not indicate a faulty muffler.
102,000 Miles (170,000 km) Inspect exhaust system for leaks, damage or loose
• Inspect and lubricate automatic transmission shift • Lubricate steering linkage suspension, driveshaft
linkage. U-joint, if equipped with grease fittings, and lubricate
• NOTE: It is normal for a certain amount of moisture slip-yoke (if equipped). (2)
seams. The presence of soot, light surface rust or 117,000 Miles (195,000 km)
• Lubricate steering linkage suspension, driveshaft • Inspect engine cooling system, hoses, and
U-joint, if equipped with grease fittings, and lubricate clamps; check coolant strength every
slip-yoke (if equipped). (2) 15,000 miles (25,000 km) or 12 months.
1995 F 150, F 250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain July 1994
M M

ALL RIGHTS RESERVED

(3) City delivery vehicles and other unique applications that
(50,000 km) or 30 months. (1)
require constant turning may need more frequent tire
• Replace spark plugs. rotation. Tire rotation may be determined by tire wear.
• Replace crankcase. (1) (5) Wheellugnuts must be retightened to proper torque

specifications at 500 miles (800 km) of new vehicle
• Replace PCV valve. operation 100 miles (160 km) and 500 miles (800 km)
• Check thermactor hoses and clamps for vehicles equipped with dual rear wheels or equipped
for snowplowing). Proper torque specifications are
(recommended but not required).
• Inspect accessory drive belts. specifications at 500 miles (800 km) after (1) any wheel
change or (2) any other time the wheellugnuts have
• Inspect and lubricate automatic transmission shift been loosened.
linkage.
(6) On dual rear wheel vehicles, rotate front tires side to
• NOTE: It is normal for a certain amount of moisture side without disturbing the rear tires.
(7) At 60,000 miles (96,000 km) dealer will replace the PCV
seams. The presence of soot, light surface rust or valve at no cost except on Canada and California
moisture does not indicate a faulty muffler. vehicles.
exhaust shielding. LUBRICATION
U-joint, if equipped with grease fittings, and lubricate Lubrication Points
WARNING: THE AMERICAN PETROLEUM
• Lubricate throttle kickdown or TV lever ball studs. INSTITUTE (API) HAS ANNOUNCED THAT
• Inspect disc brake system and lubricate caliper CONTINUOUS CONTACT WITH USED MOTOR OIL
slide rails. (2) HAS CAUSED SKIN CANCER IN LABORATORY
MICE. THE EFFECTS OF USED MOTOR OIL ON
• Change fuel filter (recommended but not required for HUMANS HAS NOT BEEN ESTABLISHED. IT IS
RECOMMENDED, HOWEVER, THAT AS A
• Inspect and lubricate front wheel bearings. (2) PRECAUTIONARY MEASURE, HUMANS PROTECT
• Inspect parking brake system for damage and THEIR SKIN BY WASHING WITH SOAP AND
operation. WATER AFTER COMING IN CONTACT WITH USED
MOTOR OIL.
Important lubrication points for typical chassis and
(1) Extremely dusty conditions will require more frequent
replacement of the air filter. Check the air filter at
engines are shown in the following illustrations.
3,000 miles (5,000 km). If it is dirty, replace it and then Vehicles with optional equipment may have slightly
keep replacing it at the same interval every 3,000 miles different or additional lubrication points. When special
(5,000 km). If it is not dirty, check it again at 6,000 miles equipment or accessories are installed on the truck,
(9,500 km) and again at 9,000 miles (14,500 km) until consult the manufacturer's literature for lubrication
the required maintenance interval is established. procedures. A table of recommended lubricants is
Do not go beyond 30,000 miles (48,000 km). included at the end of this section.
(2) If the vehicle is driven 0 ft road" in water that is deeper
11
than the hubs (1/2 wheel height), then these items must
be serviced daily.
(Continued)

ALL RIGHTS RESERVED
LUBRICATION (Continued)
Service Points - Engine Compartment

4.9L Engine, F-Series
~
~ RADIATOR COOLANT LEVEL
AIR FILTER REFER TO THE
FA-1048 'APPROPRIATE SHOP
REPLACEMENT AT MANUAL FOR CHECKING,
RECOMMENDED DRAIN AND FILL PROCEDURE
INTERVAL
BATTERY
BXT-65-650
POWER STEERING PUMP

DIPSTICK FLUID SHOULD
BE IN THE FULL HOT
OR FULL COLD RANGE,
DEPENDING ON FLUID
TEMPERATURE
OIL FILTER
FL-1A ENGINE OIL OIL LEVEL MAY BE IN THIS
REPLACE AT FILLER CAP RANGE AFTER AN OIL CHANGE
RECOMMENDED AUTOMATIC TRANSMISSION
INTERVAL DISTRIBUTOR.....--l---~ :~
FLUID LEVEL DIPSTICK
CHECK WITH ENGINE
RUNNING AND
TRANSMISSION IN PARK
BRAKE MASTER FLUID LEVEL AT
CYLINDER-CHECK OPERATING TEMPERATURE
FLUID LEVEL 66° TO trc (150° TO 170°F)
PCV VALVE
REPLACE AT FLUID LEVEL AT ROOM
COAT GASKET RECOMMENDED TEMPERATURE 21° TO 35°C
WITH ENGINE INTERVAL (70° TO 95°F)
OIL
~
HYDRAULIC CLUTCH
FLUID RESERVOIR
g DO NOT
DRIVE MARK
CHECK FLUID LEVEL WITH
DIAPHRAGM REMOVED
Y2737..J

ALL RIGHTS RESERVED
5.0L and 5.8L Engines, F-Series and Bronco (5.8L Lightning Similar)
RADIATOR COOLANT LEVEL
REFER TO THE MAINTENANCE
SECTION IN THE APPROPRIATE
~. ~ SHOP MANUAL FOR CHECKING,
:'l DRAIN AND FILL PROCEDURE
AIR FILTER
FA-1046
REPLACE ELEMENT
AT RECOMMENDED
INTERVAL
FLUID LEVEL AT
POWER STEERING PUMP OPERATING TEMPERATURE
DIPSTICK FLUID SHOULD 6fr TO 770Ct (1 sao TO 17ooF)
BE IN THE FULL FLUID LEVEL AT ROOM
HOT OR FULL COLD TEMPERATURE 21° TO 36°C
RANGE, DEPENDING ON (700 TO 96°F)
FLUID TEMPERATURE
AUTOMATIC TRANSMISSION
FLUID LEVEL DIPSTICK
CHECK WITH ENGINE
RUNNING AND
PCV VALVE
L- -t-_ _~~.::::===---.l--_EV·98·C
REPLACE AT
RECOMMENDED ~
INTERVAL
OIL FILTER
HYDRAUUC FL-820
CLUTCH FLUID REPlACE AT
RESERVOIR- RECOMMENDED
CHECK FLUID INTERVAL
LEVEL WITH
DIAPHRAGM REMOVED COAT GASKET WITH
ENGINE Oil
OIL LEVEL MAY BE IN THIS
RANGE AFTER AN OIL CHANGE
Y4371-E

ALL RIGHTS RESERVED
00-03-24 Maintenance and Lubrication OO-03-2~
7.3L Diesel Engine, F-Series
ADD 1 QUART KEEP THE OIL IN THIS RANGE
2:~FULL \
RANGE AFTER AN OIL CHANGE
RADIATOR COOLANT LEVEL
FLUID lEVEL DIPSTICK
REFER TO THE APPROPRIATE
CHECK WITH ENGINE SHOP MANUAL FOR
RUNNING AND
CHECKING, DRAIN AND
FILL PROCEDURE
POWER STEERING PUMP BATTERY
DIPSTICK FLUID SHOULD BXT-65-850 (2)
BE N THE FULL HOT OR
FULL COLD RANGE, DEPENDING
ON FLUID TEMPERATURE
OIL FILTER
FL-784
REPLACE AT
--!!!I"ooo"- ENGINE OIL
FILLER CAP
RECOMMENDED ENGINE FUEL FILTEAl
INTERVAL COOLANT WATER SEPARATOR
RECOVERY FD-829
RESERVOIR REPLACE AT
RECOMMENDED
INTERVAL
ENGINE OIL
1fmI~--+- LEVEL DIPSTICK
FLUID LEVEL AT
OPERATING TEMPERATURE
880 TO noc (1 SOO TO 1700F)
COAT GASKET WITH
AIR FILTER FLUID LEVEL AT ROOM
ENGINE OIL
FA-1057 TEMPERATURE 10° TO 35°C
REPLACE ELEMENT (500 TO 95°F)
AT RECOMMENDED
CLUTCH FLUID INTERVAL
RESERVOIR-CHECK DO NOT
FLUID LEVEL WITH DRIVE MARK
DIAPHRAGM REMOVED Y2740-J
ALL RIGHTS RESERVED
7.5L Engine, F-Series
POWER STEERING PUMP

DIPSTICK FLUID SHOULD
BE IN THE FULL HOT ENGINE COOLANT RADIATOR COOLANT LEVEL
WINDSHIELD WASHER RECOVERY
OR FULL COLD RANGE, RESERVOIR REFER TO THE APPROPRIATE SHOP
DEPENDING ON FLUID RESERVOIR AND MANUAL FOR CHECKING,
TEMPERATURE ENGINE COOLANT DRAIN AND FILL PROCEDURE
RECOVERY RESERVOIR
BATTERY
BXT-65·650
AIR FILTER
I FA-1046 REPLACE
ELEMENT AT
RECOMMENDED DISTRIBUTOR
INTERVAL
ENGINE
OIL FILLER --~--..o FLUID LEVEL AT
CAP OPERATING TEMPERATURE
ENGINE OIL _ .............~ 66° TO 77°C (150° TO 170°)
LEVEL DIPSTICK FLUID LEVEL AT ROOM
TEMPERATURE 21° TO 35°C
(70° TO 95°)
BRAKE MASTER
CYLINDER-CHECK DO NOT
FLUID lEVEL DRIVE MARK
e
KEEP THE OIL IN THIS RANGE AUTOMATIC TRANSMISSION
~ FLUID LEVEL DIPSTICK
c: ~FULL \ CHECK WITH ENGINE
RUNNING AND TRANSMISSION
'/
ADD 1 QUART

HYDRAULIC
CLUTCH FLUID
RESERVOIR
CHECK FLUID
OIL FILTER
Fl·1HP
REPLACE AT
IN PARK
PCV VALVE
EV-154
REPLACE AT
RECOMMENDED
RANGE AFTER AN OIL CHANGE LEVEL WITH RECOMMENDED
DIAPHRAGM REMOVED INTERVAL INTERVAL
~=:::::iiiiiiijilll"'"
COAT GASKET
WITH ENGINE OIL
Y4372·D

ALL RIGHTS RESERVED
00-03·26 Maintenance and Lubrication 00-03-26
Service Points - Chassis

F-150, F-250, F-350 4x4 and Bronco
LUBRICATE WITH MULTI-PURPOSE GREASE

D7AZ-19584-AA (ESR-MIC59-A) OR PREMIUM
LONG-LIFE GREASE XG-1-C OR -K
(ESA-M1C75-B) OR EQUIVALENT
PITMAN ARM
CONNECTION
GREASE FITTING
CHECK FRONT AXLE
LUBRICANT LEVEL STEERING LINKAGE
GREASE FITTiNGS
(4 PLACES) IF SO EQUIPPED
* REPACK FRONT WHEEL

BEARING AND LOCKING
HUBS (BOTH SIDES)
LUBRICATE DISC BRAKE
CALIPER SLIDE RAILS AND
KNUCKLE INNER PAD SLOT
BALL STUD - LUBRICATE WITH
MULTI-PURPOSE GREASE LUBRICATE FRONT SPINDLE
07AZ-19584-AA OR MANUAL NEEDLE BEARINGS
PREMIUM LONG-LIFE GREASE TRANSMISSION
XG-1-C (ESA-MIC75-B) FILL PLUG LUBRICATE UNIVERSAL JOINT
OR EQUIVALENT CHECK LEVEL --+-lII--4~'''l FITTINGS AND
(ON DRIVER'S SIDE) ~~-----~-"""I SPLINE FlmNG (SLIP YOKE)
(ON PASSENGER (IF SO EQUIPPED)
SIDE FOR 4-SPEED)
LUBE CLUTCH
CHECK FLUID LEVEL RELEASE LEVER
TRANSFER CASE
·DRAIN AND REFilL
TRANSFER CASE
LUBRICATE
SLIP YOKE SPLINE
FITTING IF SO
EQUIPPED
THROTTLE VALVE (TV)

CABLE LINKAGE 5.0L
MFI AOD TRANSMISSION ONLY
KICKDOWN CABLE LINKAGE
4.9L MFI AND 7.5L MFI
C-6 TRANSMISSION ONLY
~
TRANSMISSION
DIPSTICK
(AUTOMATIC)
·lUBRICATE
TRANSFER CASE
SHIFT LEVER PIVOT ---=::::=~"--'"~-~
BOLT AND CONTROL
ROD CONNECTING PINS
·DAILY WHEN OPERATING IN DEEP WATER

V1031-Z
1995 ~-150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
F-150, F-250, F-350 4x2 and F-Super Duty
GREASE
GREASE FITTINGS
FITTING
SPINDLE
GREASE
FITTINGS
SPINDLE
GREASE
SOUD I-BEAM FRONT AXLE F-SUPER DUTY FITTINGS
NOTE: USE PREMIUM LONG-UFE GREASE
XG-1-C OR -K (ESA-MIC75-B) OR EQUIVALENT
NOTE: USE PREMIUM LONG-UFE

GREASE XG-t-C OR -K
(ESA-MIC75-B) OR EQUIVALENT
~
TRANSMISSION IN FITTING ONLY
DIPSTICK
(AUTOMATIC)
GREASE FITTING TIE ROD GREASE

FITTING
CAST TWIN I-BEAM FRONT AXLE F-150-25G-F-350 (4x2)
NOTE: USE MULTI-PURPOSE PREMIUM LONG-UFE
GREASE XG-t-C OR -K (ESA-MIC75-B)
OR EQUIVALENT
KING PIN (TWO GREASE
FITTINGS ON EACH)
F-SUPER DUTY AND -----~
F-350 (4x4) ONLY TIE ROD - GREASE FITTING ON EACH SIDE
(FORWARD OF AXLE ON 4 WHEEL DRIVE)
REPACK FRONT
WHEEL BEARINGS
LUBRICATE DISC
BRAKE CALIPER
SLIDE RAILS AND
KNUCKLE INNER
PAD SLOTS
LUBRICATE WITH MULTI-PURPOSE GREASE LUBRICATE

D7AZ-19584-AA (ESR-M1C59-A) OR PREMIUM UNIVERSAL
LONG-LIFE GREASE XG-1-C OR -K (ESA-M1C75-B) JOINT FITTINGS
MANUAL (IF SO EQUIPPED)
OR EQUIVALENT
TRANSMISSION
FILL PLUG
CHECK LEVEL
LUBRICATE
(ON DRIVER'S SIDE
UNIVERSAL JOINT SPLINE
FOR 5 SPEEDS)
FITTING (SLIP YOKE)
(ON PASSENGER SIDE FOR
4 SPEED)
BALL STUD
LUBRICATE WITH MULTI-PURPOSE
GREASE D7AZ-19584-AA OR PREMIUM
LONG-LIFE GREASE XG-1-C OR -K
(ESA-MIC75-B) OR EQUIVALENT
PARKING BRAKE
FILL PLUG
CHECK LEVEL
'/
TRANSMISSION T-V
LEVER PART OF TRANSMISSION
REFERENCE
THROTTLE VALVE (TV) CABLE LINKAGE
S.OL MFI ENGINE AOD TRANSMISSION ONLY
KlCKDOWN CABLE LINKAGE, 4.9L MFI,
5.8L MFI, 7.5L MFI F-SUPER DUTY ONLY
Y1026-R

ALL RIGHTS RESERVED
00·03·28 Maintenance and Lubrication 00·03·28
F-Super Duty Commercial and Motorhome Chassis
REPACK FRONT
WHEEL BEARINGS
LUBRICATE DISC BRAKE
CALIPER SLIDE RAILS
AND KNUCKLE INNER
SPINDLE PIN (TWO GREASE PAD SLOTS
FITIINGS ON EACH SIDE)
lJoooo---....... J L...tl-.-;[,j~i----- SPINDLE BOLT
2 EACH SIDE
LUBRICATE
CLUTCH RELEASE--------- --J~~
LEVER TIE ROD,

1 FiniNG ON
MANUAL TRANSMISSION EACH SIDE
FILL PLUG
CHECK lEVEL PARKING BRAKE
(ON DRIVER'S SIDE) FilL PLUG
CHECK lEVEL
LUBRICATE
UNIVERSAL JOINT LUBRICATE
FITTING ~--------~!-----I~'5) UNIVERSAL JOINT SPLINE
FITTING (SLIP YOKE)
(3 PLACES OR MORE
DEPENDING ON WHEELBASE)
NOTE: USE PREMIUM LONG LIFE GREASE REAR AXLE FILL PLUG
XG·1 ..C OR·K OR EQUIVALENT F..SUPER DUTY
(DANA MODEL 80 AXLE)
Y4153..F
SPECIFICATIONS
LUBRICANT AND MAINTENANCE MATERIALS SPECIFICATIONS

Item Ford Part Name Ford Part Number Ford Specification
Windshield Washer Reservoir Ultra-Clear Windshield C9AZ-19550-AA or BA ESR-M17P5-A
Washer Solvent
Body Hinges, Latches, Door Striker Plates and Rotor, Multi-Purpose Grease D7AZ-19584-AA ESR-M 1C 159-A
Seat Tracks, Door Tracks and Checks, Hood Latch
and Auxiliary Latch
Lock Cylinders, Outside Spare Tire Lock Lock Lubricant D8AZ-19587-AA ESB-M2C20-A
(Continued)
1995 F-150, F-250, F-350, Bronco, F-Super Duty Ppwertrain, Drivetrain July 1994
ALL RIGHTS RESERVED
)0-03-29 Maintenance and Lubrication 00-03-29
;PECIFICATIONS (Continued)
LUBRICANT AND MAINTENANCE MATERIALS SPECIFICATIONS (Cont'd)

Front Axle Spindle Pins, Front and Rear Spring Premium Long-Life XG-1-C ESA-M1C75-B
Shackle Pins, Steering Column U-Joints, Clutch Grease
Linkage Fittings, Universal Joints, Joints with Zerk
Fittings, and Slip-Yoke Pivots, Parking Brake Linkage
Pivots and Clevises, Transmission Control Linkage
Pivots
Front Wheel Bearings and Rear Wheel Bearings Premium Long-Life XG-1-C ESA-M 1C75-B
Brake and Clutch Pedal Shaft Grease
4x4 Front Drive Axle, U-Joints, Wheel Bearings and High Temperature 4x4 E8TZ-19590-A ESA-M1C198-A
Spindle Needle Bearings Front Axle and Wheel
Bearing Grease
Power Steering Reservoir Premium Power Steering E6AZ-19582-AA ESW-M2C33-F
Fluid
Clutch Release Lever at Pivots Premium Long-Life XG-1-C ESA-M1C75-B
Grease
Engine Oil - All Gasoline Engines Motorcraft Motor Oil XO-5W30-QSP ESE-M2C 153-E
5W30 and 10W30 Super XO-10W30-QSP and API SG/CC,
Premium SG/CD or SG/CC
Engine Oil - Diesel 8 Motorcraft Motor Oil XO-15W40-QSD API SG/CE or SG/CD and
(Consult Respective Engine Owner's Guide for 15W40 Super Duty XO-30-QSD ESE-M2C 153-E
Recommendations) SAE-30 Super Duty
Engine Oil Filter - Diesel (7.3L) Oil Filter E3TZ-6731-A (FL-784) -
Engine Oil Filter - Gasoline, 4.9, 5.0, 5.8L Motorcraft Long-Life Oil D9AZ-6731-A (FL-1A) ES-E 1ZE-6714-AA
Filter
Engine Oil Filter - Gasoline, 7.5L Motorcraft Long-Life Oil E7TZ-6731-A ES-E 1ZE-6714-AA
Filter (FL-1HP)
C6, E40D and 4R70W Automatic Transmission Motorcraft MERCON@ XT-2-QDX or DDX MERCON@
Multi-Purpose Automatic E4AZ-19582-B ESP-M2C166-H
Transmission Fluid
Accelerator Control Kickdown (Automatic 6 Cyl.) Premium Long-Life XG-1-C ESA-M 1C75-B
Grease
Speedometer, Parking Brake Cable Speedometer Cable E6TZ-19581-A ESF-M1C60-A
Lubricant
Steering Linkage - Lubricate Only Where Equipped Premium Long-Life XG-1-C ESA-M1C75-B
with Grease Fittings Grease
Accelerator Linkage - Ball Socket Premium Long-Life XG-1-C ESA-M 1C75-B
Grease
Ford Axles (Conventional and Limited-Slip)bC Premium Rear Axle XY-90-QL ESP-M2C 154-A
Lubricant
Transfer Case - Four-Wheel Drive Motorcraft MERCON@ XT-2-QDX or DDX MERCON@
Transmission Fluid
Transfer Case Shift Lever Pivot Bolt and Control Rod Premium Long-Life XG-1-C ESA-M1C75-B
Connecting Pins Grease
Rear Dana Axles and Dana Limited-Slip Rear Axles d Premium Rear Axle C6AZ-19580-E ESW-M2C105-A
Lubricant
Front Dana Axles 44 and 55 4x4 GearOil F1TZ-19580-A WSL-M2C191-A
Service Fill for Severe Use, Dana, F-Super Duty Rear 75W-140 F 1TZ-19580-B WSL-M2C 192-A
Axles Synthetic Rear Axle Lube
Release Bearing for Clutches with Concentric Slave Premium Long-Life XG-1-C ESA-M 1C75-B
Cylinders Grease
Release Bearing for Conventional Systems Premium Long-Life XG-1-C ESA-M1C75-B
Grease
5-Speed Ma.nual Overdrive Transmission - Mazda Motorcraft MERCON@ XT-2-QDX or DDX MERCON@
Transmission Fluid
(Continued)
ALL RIGHTS RESERVED
SPECIFICATIONS (Continued)
LUBRICANT AND MAINTENANCE MATERIALS SPECIFICATIONS (Cont'd)

S-Speed Manual Overdrive Transmission ZF(SS-42)8 Motorcraft MERCON@ XT-2-QDX or DDX MERCON@
Transmission Fluid
Automatic Transmission Shift Linkage (F-Super Duty) Multi-Purpose Grease D7AZ-19584-AA ESR-M1C159-A
Transmission Kickdown Lever C6 (M FI Engines) Premium Long-Life XG-1-C ESA-M 1C75-B
Grease
Disc Brake, Caliper Slide Rails and Knuckle Inner and Disc Brake Caliper Slide D7AZ-19590-A ESA-M1C172-A
Outer Pad Slots Grease
F-Super Duty Parking Brake Motorcraft MERCON@ XT-2-QDX or DDX MERCON@
Transmission Fluid
Hydraulic Brake Master Cylinder - Ford High Performance C6AZ-19542-AA or BA ESA-M6C25-A
Hydraulic Clutch Master Cylinderf DOT 3 Brake Fluid or DOT
3 Equivalent Meeting
Ford Specifications
Brake and Clutch Pedal Pivots and Clevises Engine Oil SAE-10W - ESE-M2C153-E
API-SG
Manual Locking Hubs on 4x4 Steering Gear Grease C3AZ-19578-A ESW-M1C87-A
Driveshaft, Slip-Yoke and Spring Stud Shackles Premium Long-Life XG-1-C ESA-M1C75-B
Except Stripped Chassis and Motorhome Chassis Grease
Driveshaft, Universal Joints and Slip-Yoke High Temperature Grease - ESL-M1C173-A
F-Super Duty Stripped Chassis and Motorhome NLGI, NO.2
Chassis
Exhaust Control Valve Rust Penetrant D7AZ-19A501-AA ESR-M99C56-A
and Inhibitor
Engine Coolant Premium Cooling System E2FZ-19549-AA ESE-M97B44-A
Fluid
Diesel Engine Coolant Heavy-Duty Cooling FW-15 ESN-M99B 169-A
System Additive -
FW-15
Door Weatherstrips Silicone Lubricant COAZ-19553-AA ESR-M13P4-A
Driveshaft, Slip-Yoke, Double Cardan Premium Long-Life XG-1-C ESA-M1C75-B
Joint Center Ball Grease
Automatic Locking Hubs - 4x4 Automatic Hub Lock E1TZ-19590-A ESL-M1C193-A
Grease
a For Arctic winter operation below -2S·C (-10·F) but not above -7·C (20·F), use engine oil SAE SW-30 SG/CD or SG/CE.
b For Ford design rear axles: add 4 oz. of Friction Modifier CSAZ-19B546-A (EST-M2C11S-A) for complete refill of S.S-inch ring gear
limited slip rear axles. For F-250, F-350 with 10.25-inch ring gear limited slip rear axles, add 8 oz. of Friction Modifier C8AZ-19B546-A
(EST-M2C118-A).
c Synthetic High Performance Rear Axle Lubricant F1TZ-19580-B (WSL-M2C192-A) may be substituted but only after axle assembly is
completely drained.
d Add 4 oz. of Friction Modifier C8AZ-19B546-A (EST-M2C118-A or eqUivalent) to refill Dana limited slip axles.
e Synthetic MERCON®(E6AZ-19582-B) should be considered when operating under the following extreme conditions:
- Extensive idle time with transmission temperatures below -20·F (-29·C).
- Operating at maximum GCW (F-Super Duty) in hilly terrain with temperatures above 100°F (3S0C).
- Continuous (30 minutes) PTO operations.
As the clutch disc wears, the fluid level in the reservoir will rise. Fluid level above the "step" is an indication of disc wear, NOT overfill.
REFILL CAPACITIES REFILL CAPACITIES (Cont'd)

Capacities Capacities
U.S. Imperial U.S. Imperial
Component Measure Measure Liters Component Measure Measure Liters
Engine Crankcase8 (Quarts) (Quarts) 5.8L EFI (351 CID) 5.0 4.2 4.7
4.9L EFI (300 CID) 5.0 4.2 4.7 (Continued)
5.0L EFI (302 CID) 5.0 4.2 4.7
(Continued)
ALL RIGHTS RESERVED
REFILL CAPACITIES (Cont'd) REFILL CAPACITIES (Cont'd)

Capacltlea Component Capacltlea
u.s. Imperial Truck U.S. Imperial
Component Meaaure Meaaure Litera Axle (Rear) Type Meaaure Meaaure Litera
7.5L EFI (460 CID) 5.0 4.2 4.7 Ring Gear8 F-150
Tranamlaalon and Lightning 5.5 4.6 2.6
Tranafer Caae Ford F-250, 7.5 6.25 3.5
5-Speed Overdrive 3.8 3.1 3.6 Conventional F-350
(Mazda R2) and Traction-Lok
5-Speed Overdrive b 3.4 2.9 3.2 Differential, Semi
(ZF S5-42) and Full Float,
both with 10-1/4
C-6 Automatic (4x2)C 12.0 10.0 11.4
Inch Ring Gea~
C-6 Automatic (4x4)C 13.5 11.2 12.7
Dana SOC F-Super 8.3 6.9 3.9
Automatic Overdrive 14.0 11.7 13.3
Duty
(4R70W)
11.25 Inch Ring &
Elect. 4-Speed Automatic 15.7 13.1 14.8
(E40D) (4x2)C Gear Stripped
Chassis
Elect. 4-Speed Automatic 16.2 13.5 15.3
(E40D) (4x4)C Axle (Front) 4x4 Only
Transfer Case - 2.0 1.7 1.9 Front (Dana) F-150, 3.6 3.0 1.7
Borg Warner 1356d F-250
Parking Brake Assembly (Ounces) (Milliliters) - 44-IFS L.D.
(Super Duty only) 3.8 110 Front Dana F-250 3.8 3.2 1.8
a Add 1 quart (or equivalent in Imperial quarts or liters) for 50lFS Heavy
filter replacement. Duty
b Transmission fluid must be replaced every 60,000 miles
(100,000 km). Refer to the maintenance schedule. Front Dana F-3504x4 5.8 4.8 2.8
c Always use automatic transmission fluid dipstick to 60 Monobeam
determine exact fluid quantity requirement.
a Service refill capacities are determined by filling the rear
d Add an additional 3.4 Imperial quarts or 3.9 liters
axle 1/4 inch to 9/ 16 inch below the bottom of the filler
(4. 1 quarts) if a transfer case mounted PTO is used
hole.
(F-350 only).
b Service refill capacities are determined by filling the rear
axle to the bottom of filler hole..
REFILL CAPACITIES c Fill Dana rear axle to 1/4-3/ 41nch below bottom of fill hole.
Component Capacltlea NOTE: All rear axle lube quantities must be replaced
Truck U.S. Imperial every 100,000 miles (160,000 km) or if the axle has
Axle (Rear) Type Meaaure Meaaure Litera been submerged in water. Otherwise, the lube should
not be checked or changed unless a leak is
(Pints) (Pints) suspected or repair required. Refer to the
Ford 8.8 Inch F-150 5.5 4.6 2.6 maintenance schedule.
(Continued)
REFILL CAPACITIES
Capacity
Wheelbaae Mounting
Model In./mm Front/Rear U.S. Gal. Imp.Gal. Litera
F-150 Regular Cab
4x2 (SWB) 116.8/2967 F 16.5 13.7 62
R 18.2 18.2 69
4x2 (LWB) 113/3378 F 19.0 15.8 72
R 18.2 15.2 69
4x4 (SWB)8 116.8/2967 R 18.2 15.2 69
4x4 (LWB) 113/3378 F 19.0b 15.8 72
R 18.2 15.2 69
F-150 Super Cab
4x2 (SWB) 138.8/3526 F 16.5 13.7 62
R 18.2 15.2 69
4x2 (LWB) 155/3937 F 19.0 15.8 72
R 18.2 15.2 69
(Continued)
ALL RIGHTS RESERVED
00-03-32 ;' ,
Maintenance and Lubrication 00-03-32
REFILL CAPACITIES (Cont'd)

Capacity
Wheelbase Mounting
Model In./mm Front/Rear u.S. Gal. Imp. Gal. Liters
4x4(LWB) 155/3937 F 19.0 15.8 72
R 18.2 15.2 79
F-250 Regular Cab
4x2 133/3378 F 19.0° 15.8 72
R 18.2 15.2 69
4x4 133/3378 F 19.0b 15.8 72
R 18.2 15.2 69
F-250 Super Cab and F-350 Crew Cab
4x2 (LWB) 155/3937 F 19.0 15.8 72
and 168/4278 R 18.2 15.2 69
4x4 (LWB) 155/3937 F 19.0 15.8 72
and 168/4278 R 18.2 15.2 79
F-350 Super Cab
4x2 (LWB) 155/3937 F 19.0 15.8 72
R 18.2 15.2 69
F-350 Pickup/Chassis Cab 4x2 133/3378 F 19.0° 15.8 72
R 18.2 15.2 69
F-350 Pickup / Chassis Cab 4x4 133/3378 F 19.0b 15.8 72
R 18.2 15.2 69
F-350 SRW Chassis Cab 4x2 136.8/3475 F 19.0 15.8 72
R 19.0 15.8 72
F-350 SRW Chassis Cab 4x2 160.8/4085 F 19.0° 15.8 72
R 19.0 15.8 72
F-350 DRW Chassis Cab 4x4 136.8/3474.7 F 19,0° 15.8 72
R 19.0 15.8 72
F-350 DRW Chassis Cab 4x2 160.8/4085 F 19.0° 15.8 72
R 19.0° 15.8 72
F-Super Duty Chassis Cab 4x2 136.8/3475 F 19.0° 15.8 72
R 19.0 15.8 72
R 19.0 15.8 72
R 19.0 15.8 72
a Dual tanks are standard except on Regular Cab (4x4) (SWB).
b With E40D transmission Diesel Engine 18.3 Imp. gals., 83 liters (22.0 gallons) and all other EFI Engines 13.7 Imp. gals., 62 liters
(16.5 gallons).
c With Diesel Engine 16.7 Imp. gals., 76 liters (20.0 gallons).
COOLING SYSTEM CAPACITY COOLING SYSTEM CAPACITY (Cont'd)

U.S. Imp. u.S. Imp.
Engine Truck Equipment Ots. Ots. Liters Engine Truck Equipment Ots. Ots. Liters
4.9L EFI F-150, Manual 13.0 10.0 12.0 4.9L EFI F-150, Automatic 14.0 11.0 13.0
(300 CID) F-350 Transmission (300 CID) F-350 Transmission
1-6 with Standard 1-6 with Super or
Cooling Standard
Cooling
4.9L EFI F-150, Manual 14.0 11.0 13.0
(300CID) F-350 Transmission (Continued)
1-6 with Air
Conditioning or
Super Cooling
(Continued)

ALL RIGHTS RESERVED
COOLING SYSTEM CAPACITY (Cont'd) COOLING SYSTEM CAPACITY (Cont'd)

U.S. Imp. u.S. Imp.
Engine Truck Equipment Qts. Qts. Liters Engine Truck Equipment Qts. Qts. Liters
4.9LEFI F-150, Manual 15.6 12.3 14.8 5.8L EFI F-150, Manual and 18.0 14.4 17.0
(300 CID) F-350 Transmission (351 CID) F-350 Automatic
1-6 and Automatic V-8 Transmission
Transmission with Super Cool
with Air or Super Cool
Conditioning and and Air
Super Cooling Conditioning
4.9L EFI F-150, Automatic 15.5 12.4 14.7 7.5L EFI F-250, All 19.8 15.8 18.7
(300CID) F-350 Transmission (460 CID) F-350
1-6 with Air V-8
Conditioning
5.0L EFI F-150, Manual 15.7 12.5 14.9 COOLING SYSTEM CAPACITY, 7.3L DIESEL
(302 CID) F-250 Transmission
V-8 with Standard Component u.S. Imp. Metric
Cool Cooling System
5.0LEFI F-150, Automatic 16.5 13.2 15.6 (Including Heater)- 20 Qts. 240ts. 27 Liters
(302 CID) F-250 Transmission Engine on
V-8 with Standard (with 1 Ouart Filter Change) 9.5
Cool 7.3L Diesel 100ts. 8.30ts. Liters
5.0L EFI F-150, Manual or 16.4 13.0 15.5 19.0 15.8
(302 CID) F-250 Automatic Fuel Tank Gals. Gals.
V-8 Transmission Standard 18.2 15.2 72 Liters
with Air Dual Tanks Gals. Gals. 69 Liters
Conditioning
.75
5.0L EFI F-150, Manual or 18.3 14.6 17.3 Power Steering 1.6 Pts. 1.6 Pts. Liters
(302 CID) F-250 Automatic
V-8 Transmission Radiator Cap 13psi 90kPa
with Super Cool b
Manual Transmlsslon 3.40ts. 2.80ts. 3.20ts.
or Super Cool
a Includes 4.7 liters (5 quarts) in coolant recovery.
and Air b Use synthetic Mercon@ (E6AZ-19582-B, ESR-M2C 163A2).
Conditioning
5.8L EFI F-150, Manual 15.7 12.6 14.9 WHEEL TORQUE SPECIFICATIONS
V-8 with Standard Description N·m Lb-Ft
Cool
F-150, Bronco 5-Lug Wheel 135 100
5.8L EFI F-150, Auto 16.4 13.0 15.5 1/2-20
V-8 with Standard E-350, F-250, F-350 8-Lug Wheel 190 140
Cool 9/16-18
5.8L EFI F-150, Manual and 16.4 13.0 15.5 F-Super Duty and F-Super Duty 190 140
(351 CID) F-350 Automatic Stripped Chassis Vehicles 10-Lug
V-8 Transmission Wheel 9/ 16-18
with Air
Conditioning
NOTE: Torque specifications are for clean, dirt- and
paint-free dry threads. Never use oil or grease on studs
(Continued) or nuts.

ALL RIGHTS RESERVED
02-03-1
ENGINE AND GROUP
TRANSMISSION
MOUNTING
SECTION 02·03 Engine and Transmission Mounting
VEHICLE APPLICATION ••..••••••••••.••••.•••.•..•••...•••••.•••.••02·03·1 REMOVAL AND INSTALLATION (Cont'd.)
REMOVAL AND INSTALLATION Support Insulators, Front Engine, 7.3L
Support Bracket, Transmission •••••••••••••••..•••.••••.••••02·03·2 Diesel•.••••••.•.•..••...•••.•••••••••••••••••..•••.•.•••••••••••••••••02·03·1
Support Insulator, Rear Transmission •••••••••.••.•••.••••02·03·2 SPECIFICATIONS ••••••••.••••••..••..•••••••.•••••••••••••••••••••••02-03·14
Support Insulators, Front Engine ••••.•••••.••.••..••••.••.•02·03·1 SPECIAL SERVICE TOOLS/EQUIPMENT .•••.•••••••••••••02-03·15
VEHICLE APPLICATION
F-Series and Bronco
REMOVAL AND INSTALLATION
Support Insulators, Front Engine 4. Remove the nuts and washers attaching the
insulators to the crossmember brackets. Lift the
Removal engine sufficiently to disengage the insulator stud
1. Remove the radiator overflow hose from the from the crossmember engine bracket(s).
radiator coolant recovery reservoir and detach it 5. Remove bolt attaching fuel pump shield to left
from the fan shroud (8146) (where appropriate). engine bracket, if required.
2. Remove the fan shroud attaching screws and lift 6. Remove insulator-to-engine or engine bracket
the fan shroud back and drape it onto the fan attaching nut and washer assembly. Remove
blade (8600). engine mount.
3. Support the engine (6007) using a wood block
and a jack placed under the oil pan (6675).
Support Insulators, Front Engine, 7.3L Diesel 3. Remove the fan and clutch assembly using Fan
Clutch Pulley Holder T83T-6312-A and Fan
Removal Clutch Nut Wrench T83T-6312-B.
1. Disconnect the ground cables from both 4. Raise vehicle.
batteries.
5. For the right mount, disconnect the wiring to the
2. Remove the fan shroud attaching screws and lift starter and remove the starter motor.
the fan shroud back and drape it onto the fan
blade (8600).

ALL RIGHTS RESERVED
02-03-2 Engine and Transmission Mounting 02-03-2
REMOVAL AND INSTALLATION (Continued)
6. Remove the nuts attaching the engine mount 3. Remove the bolts and nuts holding the support
insulators to the front engine support brackets brackets to the crossmember.
(6029). 4. Remove the support bracket(s) from the
7. Raise the engine and support it using a wood crossmember.
block and a jack placed under the oil pan. For installation, follow removal procedures in reverse
8. Remove the engine mount insulator to engine order. Refer to the appropriate illustration for
bolts, and the bolts securing the front engine tightening specifications.
supports to the frame crossmember.
9. Remove the engine front supports and front
support bracket together.
Support Insulator, Rear Transmission
Installation
Removal
1. Install the engine front supports and front support
brackets together. 1. Place a block of wood and a jack under the
transmission (7003).
2. Install the engine mount insulator to engine bolts,
and the bolts securing the front engine supports 2. Remove the two nuts attaching the insulator to
to the frame crossmember. Tighten to the crossmember. Remove the damper assembly
specifications. from the transmission crossmember. Raise the
transmission sufficiently to lift the insulator from
3. Lower the engine onto the mounts and install the
the crossmember.
nuts attaching the engine mounts to the front
engine support brackets. Tighten to 3. On vehicles so equipped, remove the fasteners
specifications. attaching the exhaust hanger to the rear engine
mount.
4. If the right mount was removed, install the starter
motor and connect the starter motor wiring. 4. Remove the two bolts attaching the insulator to
the transmission and remove the insulator and
5. Lower the vehicle.
retainer assembly.
6. Install the fan and clutch assembly using Fan
Clutch Pulley Holder T83T-6312-A and Fan Installation
Clutch Nut Wrench T83T-6312-B. Tighten nut to 1. Position the insulator and retainer assembly to
54-163 N·m (40-120 Ib-ft). the transmission. Install the two attaching bolts
7. Install the fan shroud and tighten the attaching and tighten to specification.
screws to specifications. 2. If so equipped, install the fasteners attaching the
8. Connect the ground cables to both batteries. exhaust hanger to the insulator. Tighten to 17-23
N·m (13-17 Ib-ft).
3. Lower the transmission and install the damper
assembly and insulator-to-front crossmember
Support Bracket, Transmission attaching nuts. Tighten to 81-109 N·m (60-80
Ib-ft).
4. Remove the jack and wood block from under the
1. Support the engine (6007) using a wood block transmission.
and jack placed under the oil pan (6675).
2. Remove the nuts and washers attaching the
insulators to the crossmember bracket(s). Lift the
engine sufficiently to disengage the insulator stud
from the crossmember engine bracket(s).

ALL RIGHTS RESERVED
Engine Front Supports and Insulator Assembly, F-150, F-250, F-350 and Bronco with 5.0l and 5.al Engine
.-
FRONT OF VEHICLE
...
VIEW A
F-250 (4X4) HEAVY DUTYITWIN "SEAM

FRONT SUSPENSION ONLY
5.0L AND 5.8L ENGINE INSTALLAnoN

(COIL SPRING SUSPENSION SHOWN)
N12532·A
Part Part
1 6028 Engine Support Bracket 10 387811-8100 Bolt
2 60037 Shield 11 N802114-S2 Bolt
3 6038 Engine Support Insulator 12 65094-S Rivet
4 N802114-S2 Bolt A - Tighten to 60-80 N·m
5 N800937-S? Nut (44-59 Lb-Ft)
6 N80?479-S30 1 Nut and Washer B - Tighten to 96-127 N·m
(71-92 Lb-Ft)
? 65090-S Rivet
8 65094-S Rivet
C - Tighten to 81-109 N·m
(60-80 Lb-Ft)
9 6061 Engine Support Bracket
(Continued)
1995 F-150, F-250, F-350, Bronco, F-Super Duty Powerfrain, Drivetrain July 1994

ALL RIGHTS RESERVED
Engine Front Supports and Insulator Assembly, F-250, F-350 and F-Super Duty with 7.5L Gasoline Engine and
7.3L Diesel Engine
I!/Ib
Fr:tONT OF VEHICLE
7.5L GAS ENGINE INSTALLATION
VIEW A
7.3L DIESEL ENGINE INSTALLAnON
N8418-E
Part Part
1 N800937-S7 Nut 14 68032 Engine Support Insulator
2 6028 Engine Support Bracket (RH) (LH)
3 N802114 Bolt 15 387811-S100 Screw and Washer
4 6046 Engine Support Mounting 16 60037 Engine Mount Heat Shield
Bracket (LH)
5 387811-S100 Screw and Washer A - Tighten to 53-72 N·m
(39-53 Lb-Ft)
6 6061 Engine Support Bracket (LH)
7 N800937-S7 Nut
B - Tighten to 81-109 N·m
(60-80 Lb-Ft)
8 65090 Rivet C - Tighten to 88-118 N·m
9 N807479-S30 1 Nut and Washer (65-87 Lb-Ft)
10 N803203-S 100 Bolt D - Tighten to 53-72 N·m
11 6046 Engine Support Insulator (39-53 Lb-Ft)
(RH) E - Tighten to 109-149 N·m
12 389696 Bolt, Bracket-to-Engine (80-109 Lb-Ft)
13 68033 Engine Support Mounting
Bracket
(Continued)

ALL RIGHTS RESERVED
02-03-5 Engin. and Transmission Mounting 02-03-5
Front ·E·nglne Mounts, F-1'50, 1=--259, eF-a5E).wlth--4..--9l ."

Engine (All Transmissions) Part
Item Number Description
..
FRONT OF
VEHICLE
3
4
5
6
7
6038
6028
N802114·S2
6B032
6061
Engine Support Insulator
(RH)
Engine Support Bracket (RH)
Bolt
Engine Support Insulator
(LH)
Engine Support Bracket (LH)
8 N800937·S7 Bolt
9 N807479-S30 1 Nut
10 N800937-S7 Nut
A - Tighten to 77-103 N·m
(57·76 Lb-Ft)
(72-97 Lb-Ft)
(39-53 Lb-Ft)
N12533-A
Part
1 390979-S 100 Stud
2 387811-S100 Screw and Washer
(Continued)

ALL RIGHTS RESERVED
Engine Mounts, F-Super buty Motorhome Chassis, 7.5L Engine
N9724-B
Part Part
1 387811-S100 Screw and Washer 9 N802114-S2 Bolt
2 N803203-S100 Bolt 10 6037 Engine Support Bracket (RH)
3 6038 ~ngine Support Insulator 11 6046 Engine Support Mounting
(LH) Bracket
4 6C038 Engine Mount Heat Shield A - Tighten to 60-80 N·m
5 6B032 Engine Support Insulator (44-59 Lb-Ft)
(LH) B - Tighten to 43-57 N·m
6 6061 Engine Support Bracket (LH) (32-42 Lb-Ft)
7 N800937-S7 Nut C - Tighten to 88-118 N·m
(65-87 Lb-Ft)
8 N807479-S30 1 Nut and Washer
(Continued)

ALL RIGHTS RESERVED
Engine Mounts, F-Super Duty Commercial Chassis, 7.3L Engine
N9726-B
Part Part
1 6046 Engine Support Mounting 10 6037 Engine Support Bracket (RH)
Bracket (RH) 11 6B033 Engine Support Insulator
2 N807823-S 100 Screw and Washer (RH)
3 6B033 Engine Support Bracket (LH) A - Tighten to 98-132 N·m
4 6B032 Engine Support Insulator (72-98 Lb-Ft)
(LH) B - Tighten to 60-80 N·m
5 387811-S100 Screw and Washer (44-59 Lb-Ft)
6 N802114-S2 Bolt C - Tighten to 43-57 N·m
(32-42 Lb-Ft)
7 N800937-S7 Nut
8 N807479-S30 1 Nut and Washer
0 - Tighten to 88-118 N·m
(65-87 Lb-Ft)
9 6028 Engine Support Bracket (LH)
(Continued)

ALL RIGHTS RESERVED
02-03-8 Engine and Transmission Mounting 02-03·8
Transmission Support, F-150, F-250, F-350 Regular Cab, SuperCab and F-Super Duty 4x2, All Transmissions
ExceptE40D
FRONT OF VEHICLE
~
2
VIEW FOR C6, 4R70W AUTOMATIC TRANSMISSION

AND M50D MANUAL TRANSMISSION
VIEW A
MANUAL TRANSMISSION N8423-E
Part Part
1 6096 Engine Support Bracket (RH) 7 N621945-S2 Nut and Washer
2 6A023 Engine Support 8 N802114 Bolt
3 6096 Engine Support Bracket (LH) 9 N800937-S7 Nut
4 6068 Engine Support Insulator A - Tighten to 88-118 N·m
5 391558-S2 Screw and Washer (65-87 Lb-Ft)
6 4A263 Damper (F-250, 7.3L 4x2 B - Tighten to 77 -103 N·m
with Manual Transmission (57-76 Lb-Ft)
and F-350, 7.3L, 133-lnch C - Tighten to 53-72 N·m
Wheelbase, 4x2 with Manual (39-53 Lb-Ft)
Transmission)
(Continued)

ALL RIGHTS RESERVED
Transmission Support, F-350 Chassis Cab and F-Super Duty Chassis Cab, All Transmissions Except E40D
FRAME HOLE
...
FRONT OF VEHICLE
MANUAL TRANSMISSION
FRAME HOLE N8424-B
Part Part
1 N802114-S2 Bolt B - 1820.0mm
2 6096 Engine Support Bracket (LH) (72 Inches)
3 6A023 Engine Support C - 1852.3mm
(73 Inches)
4 N800937-S7 Nut
(39-53 Lb-Ft)
(Continued)
1995 F-150, F-250, F-350, Brqnco, F-Super Duty Powertrain, Drivetrain July 1994
ALL RIGHTS RESERVED
Transmission Support, F-150 5.8L 4x2 Lightning,

E40D Transmission Part
3 391558-S 100 Screw and Washer
4 7108 Transmission Support
Bracket
5 N621945-S2 Nut
6 6A023 Engine Support
(65-87 Lb-Ft)
N11198-B
Part
1 7003 E40D Transmission -
Reference
2 6068 Engine Support Insulator
(Continued)
ALL RIGHTS RESERVED
Transmission Support, F-150, F-250 and Bronco 4x4, All Transmissions Except E40D
~
4
I I
VIEW FOR M50D

MANUAL TRANSMISSION
~
FRONT OF VEHICLE
3
VIEW FOR C-6 AND 4R70W

AUTOMATIC TRANSMISSION N8425-D
Part Part
1 6096 Engine Support Bracket (RH) 7 N802114 Bolt
2 6A023 Engine Support 8 N800937 Nut
3 6096 Engine Support Bracket (LH) A - Tighten to 88-118 N·m
4 6068 Engine Support Insulator (65-87 Lb-Ft)
5 391558-S 100 Screw and Washer B - Tighten to 53-72 N·m
(39-53 Lb-Ft)
6 N621945 Nut
(Continued)
ALL RIGHTS RESERVED
Transmission Support, F-350 Chassis Cab 4x4, All

Transmissions Except E40D Part
3 6A023 Engine Support
4 N800937-S7 Nut
(39-53 Lb-Ft)
.,
FRONT OF VEHICLE
c-6 AUTOMAnC TRANSMISSION
@
4
M50D MANUAL TRANSMISSION

N9216-D
Part
1 N802114-S2 Bolt-Hex
2 6096 Engine Support Bracket (RH)
(Continued)
Transmission Support, F-150, F-250, F-350, F-Super Duty and Bronco with E40D Transmission
VIEW A
F-160-360 (4x2) N9217-D
Part Part
1 6096 Engine Support Bracket (RH) 4 6068 Engine Support Insulator
2 6A023 Engine Support 5 391558-S 100 Screw and Washer
3 6096 Engine Support Bracket (LH) 6 N621945-S2 Nut and Washer
(Continued) (Continued)
ALL RIGHTS RESERVED
Part Part
7 N802114 Bolt A - Tighten to 88-118 N·m
8 N800937-S7 Nut (65-88 Lb-Ft)
(Continued)
(39-53 Lb-Ft)
Transmission Support, F-150, F-250, F-350, F-Super Duty and Bronco with E40D Transmission (Continued)
F-150-350 (4x4)
~UPERDUTYANDBAONCO
N9218-D
Part Part
1 6A023 Engine Support 6 N802114 Bolt
2 6096 Engine Support Bracket (LH) 7 N800937-S7 Nut
3 6068 Engine Support Insulator A - Tighten to 88-118 N·m
4 391558-S 100 Screw and Washer (65-88 Lb-Ft)
5 N621945-S2 Nut and Washer B - Tighten to 53- 77 N·m
(39-53 Lb-Ft)
(Continued)
ALL RIGHTS RESERVED
02·03·14 Engine and Transmission Mounting 02·03·14
REMOVAL AND INSTALLATION (Continued) SPECIFICATIONS
Transmission Support, F-Super Duty Commercial TORQUE SPECIFICATIONS

and Motorhome Chassis
De8crlptlon N·m Lb·Ft
Front Engine Support 96-127 71-92
Insulator-to-Crossmember Bracket
Attaching Nuts (7.3L Diesel)
Fan Shroud Attaching Screws 6-8 53-71
(7.3L Diesel) (Lb-In)
Exhaust Hanger-to-Rear 17-23 13-17
Transmission Support Insulator
Fasteners
Rear Transmission Support 81-109 60-80
Insulator-to-Front Crossmember
Nuts
Engine Support Bracket Nuts (5.0L 60-80 44-59
and 5.8L Engines)
Engine Support Bracket (RH) Nuts 53-72 39-53
(4.9L, 7.3L and 7.5L Engines)
REAR ENGINE MOUNTS Eng;'" ~ Support Mounting Bracket 81-109 60-80

(7.S·~ and 7.5L Engines)
MAIN VIEW ~-
Engine Support Bracket (RH) Nut 88-118 65-87

and Washer (7.3L and 7.5L
Engines)
Engine Support Mounting Bracket 109-149 80-109
Bolt (7.3L and 7.5L Engines)
Engine Support Insulator (RH) 77-103 57-76
Screw and Washer (4.9L Engine)
Engine Support Insulator (LH) Nut 98-132 72-97
(4.9L Engine)
Engine Support Insulator (LH) 60-80 44-59
Screw and Washer (7.5L Engine)
Engine Support Bracket (LH) Nut 43-57 32-42
(7.5L Engine)
Engine Support Insulator Nut and 88-118 65-87
Washer (7.5L Engine)
Engine Support Mounting Bracket 98-132 72-98
(RH) Screw and Washer (7.3L
Engine)
LH Engine Support Bracket-to-LH 60-80 44-59
Engine Support Insulator Screw
and Washer (7.3L Engine)
Part Engine Support Bracket (LH) Nut 43-57 32-42
Item Number Description (7.3L Engine)
1 5028 Crossmember RH Engine Support Bracket-to-RH 88-118 65-87

Engine Support Insulator Nut and
2 6068 Engine Support Insulator
Washer (7.3L Engine)
3 44879 Washer (Used on Manual
Transmission Only) Damper Nut and Washer (4x2) 77-103 57-76
4 391558-S 100 Screw and Washer (Used on Engine Support Bracket (LH) Nuts 53-72 39-53
Automatic Transmission (4x2)
Only)
Engine Support Nut 53-72 39-53
5 58679 Bolt (Used on F-Super Duty
Commercial Chassis Only) Engine Support Insulator Screw 88-118 65-87
and Washer
6 N621945-S2 Nut and Washer
7 7003 Transmission Assembly Engine Support Bracket (LH) Nut 53-72 39-53
Manual M50D Shown - Engine Support Insulator Screw 67-95 50-70
Others Typical and Washer (Automatic
A - Tighten to 67-95 N·m Transmission) or Bolt (F-Super
(50-70 Lb-Ft) Duty Commercial Chassis)
B - Automatic Transmission Only
C - Manual Transmission Only

ALL RIGHTS RESERVED
SPECIAL SERVICE TOOLS/EQUIPMENT
SPECIAL SE~VICE TOOLS REQUIRED

Tool Number/
Description illustration
T83T-6312-A
Fan Clutch Pulley Holder
'!:: TI3T-I312-A
T83T-6312-B
Fan Clutch Nut Wrench
TI3T~12-8

ALL RIGHTS RESERVED
GROUP
ENGINE
AIR INTAKE SYSTEM •...•.................•....••..•....•....•...•...03-12-1 FUEL CHARGING AND CONTROLS, 5.0l AND
DIESEL, ENGINE, 7.3l V-8 ..........•.•.....••................•.•03-01D-1 5.8l .............•.....•...................•••..•.••.•. ~".~ •...........•.03-04A-1
DRIVE BELTS, ACCESSORY .•........................•...•....•••.03-05-1 FUEL CHARGING AND CONTROLS, 5.8l
ENGINE COOLING ...•...••........•...•••............•................03-03-1 liGHTNING ...•..•...•...•.....•.•.....•..•.....•......••...•.....••.03-04D-1
ENGINE EMISSION CONTROL ..•.....•..........•.......•.....•.•03-08-1 FUEL CHARGING AND CONTROLS, 7.3l
ENGINE SERVICE ....•.....•.....•.....••.•..•.•.......................03-00-1 DIESEL .........•.......•...•...........................•..............03-04E-1
ENGINE, 4.9l SIX-CYLINDER .•...............................•.03-01A-1 FUEL CHARGING AND CONTROLS, 7.Sl 03-04C-1
ENGINE, 5.0l AND 5.8l MFI V-8 ..................•.•..........03-01B-1 IGNITION, DISTRIBUTOR ..................•......................03-07A-1
ENGINE, 7.5l MFI V-8 ..........••.......•..•.......................03-01C-1 STARTING SYSTEM, DIESEL ENGINES ..•.•...••..........03-06B-1
..------------..---..---------..---------.11~
FUEL CHARGING AND CONTROLS, 4.9l ....•..•...••.•..•03-04B-1
SECTION 03·00 Engine Service, Gasoline

STARTING SYSTEM, GASOLINE ENGINES.. ~ •..••........03-06A-1
I/"':!,I/;:'

VEHICLE APPLICATION ........•...•.......•..............•.........03-00-2 SERVICE PROCEDURES (Cont'd.)
DESCRIPTION AND OPERATION Sand Holes or Porous Engine Castings -
Engine Identification 03-00-2 Service ..•....................•.................................03-00-18
Emission Calibration Number label ................••..03-00-3 Cylinder Heads ....•...•..........•...............................•03-00-32
Exhaust Emission Control System .....••....••.••.••.......03-00-3 Cylinder leakage Detector ..•.....•.•••.••..•.................03-00-8
Introduction ...•..................••...•.•.......................•....03-00-2 Cylinder Walls, Refinishing .•.•..•..........•.....•..........•03-00-18
Safety Certification Decal .........•....•....•...•..............03-o0-3 Cleaning ..•.....................•.................................03-00-18
DIAGNOSIS AND TESTING Cylinder Bore 03-00-19
Inspection and Verification .................................•..03-00-3 Cylinder Bore Diameter ...........•.........••........•....03-00-20
Symptom Chart............•.........................................03-00-4 Cylinder Bore Taper .•.............•.....•.....•....•........03-00-19
SERVICE PROCEDURES Cylinder Out-of-Round ..•..••..•.........................•..03-00-20
Camshaft.•...•.•.....••......................•....••.•..••....•......03-00-27 Cylinder Reboring ..••..•........•••..•.•....•................03-00-20
Camshaft End Play............•.••..•..•.........•..•.......•...•03-o0-14 Cylinder Wall Honing .....•.......................•..........03-00-20
Camshaft lobe lift .........•....................................03-00-13 Inspection ......•..........................•......................03-00-19
Compression Test .........•..............•.•.........•............03-00-7 Engine Block Plugs •..................••...•..........•....•.•...03-00-21
Compression Gauge Check ....••..........••....•.........03-00-7 Engine Oil Consumption, Excessive ..•...•...•..........03-00-10
Compression Readings - Interpreting 03-00-8 Oil Consumption Test ...•••..•••..........•...••••••..•...•.03-00-11
Example Readings.....•.....•..••.••••.••....•.....•....•...•.•03-00-8 Oil Pressure Test ............................•...........•.•...03-00-12
Test Results .................•...........••........................03-00-7 Engine Oil leaks .........................................•••........03-00-6
Connecting Rod Side Clearance 03-00-16 Fluorescent Oil Additive Method ..•........•.•...........03-00-6
Connecting Rods ...............•..................•.•............03-00-27 Pressure Method .............•...............•.....•••..•......•03-00-6
Cleaning ..........•...•....•..............•...•...................03-00-27 Testing Procedure ...•.....•......•.•..•..•...................•.03-00-6
Crankshaft .•.......••..••......•.•....•....•...........•....•.......03-00-23 Exhaust Manifold .••••...•..............•..........•..............03-00-37
Crankshaft End Play 03-00-24 Flywheel Clutch Surface Machining...•..•.........••....03-00-38
Crankshaft Runout ............•.•...........••..••....•......03-00-24 Flywheel Inspection•.•..............•..•...........•.....•....•.03-00-38
Crankshaft Sprocket or Gear 03-00-24 Transmission, Automatic .........••.......................03-00-38
Journals Refinishing .......••..........•....•.•.••..•...•....03-00-24 Transmission, Manual 03-00-38
AW:.:~~~?:~.~.~~~~I.~~~.~.~~~.I.~~
Crankshaft End Play .........••....•...............•..........••03-00-16
Crankshaft Main and Connecting Rod 03-00-17
Bearings .................•.........•.................•.•..........03-00-21 Hydraulic Valve Tappet .......•.....................•......••.•03-00-14
Crankshaft Main or Connecting Rod Bearings Hydraulic Valve Tappets................•............••.•...•.•03-00-29
- Fitting ....................................•.........••.........03-00-22 Intake Manifold...•...............................•...••...•.......03-00-37
Plastigage@ Method .........................•...•............03-00-22 Intake Manifold Vacuum Test 03-00-9
Cylinder Block ...••........•.......•.•.••...••........•............03-00-17 Vacuum Gauge Readings -
Cylinder Head Deck Flatness ....•.....•...•••...........03-o0-17 Interpreting ........•...........................................03-00-9
Main Bearing Bore Alignment ...•....•...•...............03-o0-17 leak-Down Testing 03-00-29
Leakage Points....•.................................................03-00-6

ALL RIGHTS RESERVED
03-00-2 Engine Service, Gasoline 03-00-2
SECTION 03·00 Engine Service, Gasoline

SERVICE PROCEDURES (Cont'd.) SERVICE PROCEDURES (Cont'd.)
Under Engine, with Vehicle on Hoist 03-00-7 Timing Gear Backlash, 4.9l..••...•...•....•....•...•••.•....03-00-15
Underhood ......•.....................•...................•....•...03-00-7 Valve Train Analysis - Dynamic .........•.......•••......03-00-13
With Transmission and Flywheel Positive Rotator and Valve Spring
Removed ....••..••..............••.....•..•.....................03-00-7 Keys ............•..••.........••........••.........•........••..•03-00-13
Oil leak and Valve Guide Seal Test ......................••.03-00-8 Push Rods ........•.................................•............•03-00-13
Oil Pan .......•........•..........•....•..........................••....03-00-32 Rocker Arm .....•..•.•..•........•..........•............••....••03-00-13
Oil Pump .......•........................•....••.........•....•••.•••••03-00-30 Valves and Cylinder Head ....•.....•...•.•......••........03-00-13
Pistons, Piston Pins and Piston Rings ............•..•..•03-00-24 Valve Train Analysis - Static (Engine
Cleaning ....•...............••..............•.•...•.....•....•....03-00-24 Off) ....•...•...•...••..............•....•.••..........•....•.•.....•.03-00-12
Piston and Piston Pin Fit ••......•..•••..•.•..••..•.••....••03-00-26 Positive Rotator and Keys•........••...••...............•.03-00-12
Piston Rings - Fitting.............................•........03-00-25 Push Rods .••...••........•...••....•..............•...•..........03-00-12
Pistons - Fitting ..............•.•.........•.......•..........03-00-24 Rocker Arm .•..•.•.....................•.....•••...•.........••..03-00-12
Positive Crankcase Ventilation System, Valve Spring Retainer and Valve Spring
Closed-Type •...•...••••.•••••.....•...••..........................03-00-6 Keys ...•..••...•.•..........••...•••..••••.......................03-00-12
Pressure Regulator Valve Inspection ........••...•......03-00-31 Valve Springs .........•....•..........•........•.....•......•..•03-00-12
Pressure Regulator Valve-to-Housing Valves and Cylinder Head .....•......•..•..•..............03-00-12
Clearance .........•..............................................03-00-31 SPECIFICATIONS
Push Rods ..••.•...............••.....•...•...............•..........03-00-37 Flywheel Dimensions ....•........•....••...•........•..........O3-00-39
Rocker Arm ...•••..•.......•....•••.........•...•................•..03-00-36 SPECIAL SERVICE TOOLS/EQUIPMENT .....•.........•••03-00-39
Service limit Specifications..•..........•..................•03-00-17
Timing Chain Deflection (5.0l, 5.8l, and
7.5L) 03-00-15
VEHICLE APPLICATION Before replacing damaged or worn engine

components such as the crankshaft (6303), cylinder
All F-150, F-350, F-Super Duty and Bronco Vehicles heads (6049), valve guides, valves, camshaft (6250)
Equipped with 4.9l, 5.0l, 5.8l or 7.5l Gasoline or cylinder block (6010), make sure that partes) is not
Engines serviceable.
WARNING: TO AVOID THE POSSIBILITY OF
PERSONAL INJURY OR DAMAGE TO THE
DESCRIPTION AND OPERATION VEHICLE, DO NOT OPERATE THE ENGINE WITH
THE HOOD (16612) OPEN UNTIL THE FAN HAS
Introduction FIRST BEEN EXAMINED FOR POSSIBLE CRACKS
AND SEPARATION.
This section covers various engine tests, adjustments,
service procedures and cleaning / inspection
procedures. Engine assembly and service
specifications appear at the end of each engine
Section 03-01A, 03-o1B, and 03-01C. Engine Identification
For engine (6007) removal, disassembly, assembly, For quick engine identification, refer to the Vehicle
installation, adjustment procedures and specifications, Emission Control Information (VECI) Decal mounted
refer to Section 03-01 A, 03-01 B, or 03-01 C, under the hood (16612). This decal lists engine
depending on which engine you are servicing. information required for proper servicing of the engine
(6007). Refer to Section 00-03 for further information.
These engines incorporate a closed-type crankcase An engine identification label is also attached to the
ventilation system and exhaust emission control engine. The symbol code on the identification tag
system. All engine / emission control systems are identifies each engine for determining parts usage, for
covered in the Powertrain Control/Emissions instance, engine displacement and model year. Engine
Diagnosis Manual. 1 decal information is located in Section 03-01 A,
To maintain the required exhaust emission levels, the 03-01 B, or 03-01 C. The vehicle identification number
fuel system, ignition system and engine must be kept in (VIN) also gives engine information. The tenth digit
good operating condition and meet recommended identifies the engine. Refer to Section 00-01 for further
adjustment specifications. information.
When performing tests, adjustment or service to the
engine, system or fuel ignition system, it is essential to
follow the procedures and specifications in the
appropriate repair group in this manual, and in the
Powertrain Control/Emissions Diagnosis Manual. 1


ALL RIGHTS RESERVED
Vehicle Certification Label
CALIBRATION
,
ETALONNAGE, 1FTEF25H5PLAOOO01
CALI BRACI ON VEHICLE IDENTIFICATION NUMBER
8-25F-ROO E8AE -6E061- AAA DATE: 9·87

FRONT GAWR: 2714 LB
GVWR: 5347 LB - 2425 KG
REAR GAWR: 2683 LB
t 1231 KG 1216 KG
I
CALIBRATION
THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE
SAFETY AND BUMPER STANDARDS IN EFFECT ON THE DATE OF
REVISION NUMBER A14130-1A
VEH. IDENT. NO. 1FTEF25H5PLA 0001
TYPE PASSENGER
Emission Calibration Number Label 3H
EXTERIOR PAINT CO RS
The emission calibration number label is located on the TR
XBBBB
left side door or left door post pillar. It identifies the
engine calibration number, the engine code number
and revision level. ENGINE
MODEL
CODE
YEAR
(8th CHARACTER) A17628-A
Always refer to these labels when replacement parts

Safety Certification Decal are required or when checking engine calibrations.
For quick engine identification, refer to the Safety Engine parts often differ within a liter (or CID) family.
Certification Decal. The decal is mounted on the LH Verification of identification codes will make sure that
front door lock face panel. Find the engine code (letter the proper parts are obtained. The codes contain all
or number) on the decal, then refer to the engine pertinent information relating to dates, optional
identification chart to determine the engine type and equipment and revisions. The Ford Master Parts
size. An engine identification label is also attached to Catalog contains a complete listing of the codes and
the engine. The symbol code on the identification tag their application.
identifies each engine for determining parts usage; for
instance, engine displacement and model year. Engine
decal information is located in Section 03-01 A,
03-018, and 03-01C. Exhaust Emission Control System
These numbers are used to determine if parts are Operation, troubleshooting and required maintenance
unique to specific engines (6007). of the exhaust emission control devices used on these
engines (6007) are covered in the Powertrain
2
Control/Emissions Diagnosis Manual.
For removal and installation of exhaust emissions
components, refer to the following sections in this
manual:
• 03-03 for Engine Emission Control components
• 03-04A, 03-048, or 03-04C, for Fuel Charging
Controls components
• 03-13 for Evaporative Emissions components
• 03-14 for Electronic Engine Controls components
Inspection and Verification

1. Verify the vehicle owner's original concern by
operating the engine to duplicate the condition.
2. Inspect to determine if any of the following
mechanical concerns apply:


ALL RIGHTS RESERVED
DIAGNOSIS AND TESTING (Continued)
3. If the concern(s) remain after the inspection,

Mechanical
determine the symptoms and proceed to the
• Engine oil leaks. following Symptom Chart.
• Damaged and / or severely worn parts.
• Loose mounting bolts, studs and nuts.
Symptom Chart
ENGINE DIAGNOSIS
CONDITION POSSIBLE SOURCE ACTION
•
•• ••
Difficult Starting Burnt valve. REPLACE valve.
Worn piston. REPLACE piston.
• Worn piston ring(s). • REPLACE piston ring(s).
•• •
Worn cylinder. SERVICE or REPLACE cylinder
Damaged cylinder head gasket. block.
• Malfunctioning or damaged fuel • REPLACE cylinder head gasket.
system. • REFER to Powertrain
Control/Emission Diagnosis
3
Manual.
• Malfunctioning or damaged ignition
system.
• REFER to Powertrain
Manual. 3
• •
••
Poor Idling Damaged hydraulic valve tappet. REPLACE hydraulic valve tappet.
• Damaged hydraulic valve tappet
guide.
REPLACE hydraulic valve tappet
guide.
• Improper valve-to-valve seat
contact.
• REPLACE valve and / or valve seat.
•• •
Damaged cylinder head gasket. REPLACE cylinder head gasket.
Malfunctioning or damaged fuel
system.
Manual. 3
system.
Manual. 3
•
••
Abnormal Combustion • Damaged hydraulic valve tappet. REPLACE hydraulic valve tappet.
guide.
REPLACE hydraulic valve tappet
guide.
•• ••
Burnt or sticking valve. SERVICE or REPLACE valve.
Weak or broken valve spring. REPLACE valve spring.
• Carbon accumulation in
combustion chamber.
• ELIMINATE carbon buildup.
• Malfunctioning or damaged fuel

system.
3
Manual.
system.
Manual. 3
• Excessive Oil Consumption • Worn piston ring groove. •• REPLACE piston.
••
Sticking piston ring(s). SERVICE or REPLACE piston
Worn piston or cylinder. ring(s).
• SERVICE and / or REPLACE piston
or cylinder block.
•• Worn valve stem seal.
Worn valve stem or valve guide.
•• REPLACE valve stem seal.
REPLACE valve stem and guide.
• Leaking oil. • SERVICE oil leakage.


ALL RIGHTS RESERVED
ENGINE DIAGNOSIS (Continued)

• Engine Noise
• Excessive main bearing oil
clearance.
• ADJUST clearance or REPLACE
main bearing.
• Seized or heat damaged main
bearing.
• REPLACE main bearing.
• Excessive crankshaft end play. • ADJUST end play or REPLACE

crankshaft.
• Excessive connecting rod bearing
oil clearance.
connecting rod.
• Heat damaged connecting rod
bearing.
• REPLACE connecting rod bearing.
••
Damaged connecting rod bushing.
Worn cylinder.
•• REPLACE connecting rod bushing.
SERVICE or REPLACE cylinder
block.
••• •••
Worn piston or piston pin. REPLACE piston or piston pin.
Damaged piston ring(s). REPLACE piston ring(s).
Bent connecting rod. REPLACE connecting rod.
• Malfunctioning hydraulic valve
tappet.
• REPLACE hydraulic valve tappet.
• Excessive hydraulic valve tappet

clearance.
hydraulic valve tappet guide.
••
Broken valve spring. ~ REPLACE valve spring.
Excessive valve guide clearance. • SERVICE clearance or REPLACE
valve guide / stem.
• MalfunctJoning or damaged cooling
system.
• REFER to Section 03-03.
• Malfunctioning or damaged fuel

system.
Manual. 4
• Leaking exhaust system. • SERVICE exhaust leakage.
• Improper drive belt tension. • REFER to Section 03-05.
• Malfunctioning generator bearing. • REFER to Section 14-02, 14-02A,
14-02B or 14-02C depending on
generator.
•
••
Loose timing chain. ADJUST or REPLACE timing chain.
Damaged timing belt tensioner. •• REPLACE timing belt tensi~ner.
• Malfunctioning water pump
bearing.
REFER to Section 03-03.
• Insufficient Power • Malfunctioning hydraulic valve

tappet.
• REPLACE hydraulic valve tappet.

guide.
• REPLACE hydraulic valve tappet
guide.
• Compression leakage at valve
seat.
• SERVICE or REPLACE valve, valve
seat and / or cylinder head.
• Seized valve stem. • REPLACE valve stem.
• •••
Weak or broken valve spring. REPLACE valve spring.
•• Damaged cylinder head gasket.
Cracked or distorted cylinder
REPLACE cylinder head gasket.
REPLACE cylinder head.
head.
• Damaged, worn or sticking piston
ring(s).
• SERVICE or REPLACE piston
ring(s).
•
••
Worn or damaged piston. REPLACE piston.
Malfunctioning or damaged fuel
system.
Manual. 4
system.
Manual. 4
• Slipping transmission. • REFER to Section 07-01A, 07-01B
or 07-01 C depending on
transmission.
• Dragging brakes. • REFER to Section 07-01 A, 07-01 B
transmission.
• Incorrect tire size. • REFER to Section 07-01 A, 07-01 B
transmission.
• Damaged or plugged exhaust
system.
• REFER to Section 09-00.

1995 F-150, F-250, F-350, Bronco, F-Super Duty ~owertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
)3-00-6 Engine Service, Gasoline 03-00-6
;ERVICE PROCEDURES
Positive Crankcase Ventilation System, 2. Drain engine oil crankcase and refill with
Closed-Type recommended oil, premixed with Fluorescent Oil
Additive 112-ROO15 or equivalent. Use 29.6ml
A malfunctioning closed crankcase ventilation system (one fluid ounce) of fluorescent additive. If oil is
may be indicated by loping or rough engine idle. Do not not premixed, fluorescent additive must be added
attempt to compensate for this idle condition by to crankcase first.
disconnecting the crankcase ventilation system and
making an air by-pass or idle speed adjustment. The 3. Run engine for 15 minutes. Stop engine and
removal of the crankcase ventilation system from inspect all seal and gasket areas for leaks using
the engine (6007) will adversely affect the fuel Rotunda Oil Leak Detector Y 112-R0021 (part of
economy and engine ventilation with resultant 112-R0030 Kit) Lamp or equivalent. A clear
shortening of engine life. To determine whether the bright yellow or orange area will identify leak. For
loping or rough idle condition is caused by a extremely small leaks, several hours may be
malfunGtioning crankcase ventilation system, refer to required for the leak to appear.
5
the Powertrain Control/Emissions Diagnosis Manual. 4. If necessary, pressurize main oil gallery system
to locate leaks due to improperly sealed, loose or
cocked plugs. If flywheel bolts leak oil, look for
sealer on threads.
Engine Oil Leaks 5. Service all leaks as required.
NOTE: Due to their remote location, rear engine oil Pressure Method
leaks may be very difficult to pinpoint. This area is also
very difficult to clean. Make sure to eliminate all other As an alternative testing procedure, the crankcase
possibilities before removing an engine or transmission can be pressurized to locate oil leaks. The following
to repair a suspected leak in this area. materials are required to fabricate the tool:
When diagnosing engine oil leaks, it is important that • Air supply and air hose.
the source and location of the leak be positively
• Air pressure gauge that measures pressure.
identified prior to service. There are two methods of
diagnosing engine oil leaks. The following procedure • Air line shutoff valve.
has been found to be very effective and requires only a • Appropriate fittings to attach above parts to oil fill,
minimum of equipment. Prior to using this procedure, it PCV grommet holes and PCV fresh air hose.
is important to clean the cylinder block (6010),
cylinder heads (6049), valve covers (6582), oil pan • Appropriate plugs to seal any openings leading to
(6675) and flywheel housing areas with a suitable crankcase.
solvent to remove all traces of oil. • A solution of liquid detergent and water to be
applied with a suitable type applicator such as a
Fluorescent Oil Additive Method squirt bottle or brush.
To perform oil leak diagnosis using Rotunda Oil Leak
Fabricate the air supply hose to include the air line
Detector 112-R0030 or equivalent, perform the
shutoff valve and the appropriate adapter to permit
following procedure.
the air to enter the engine through the rocker arm
cover tube. Fabricate the air pressure gauge to a
suitable adapter for installation on the engine at the oil
fill opening.
IRotunda_I Testing Procedure

1. CAUTION: Use extreme caution when
pressurizing crankcase. Applying air
pressure above specified pressure risks
damage to seals, gaskets and core plugs.
Under no circumstances should pressure be
allowed to exceed 27 kPa (4 psi).
Open air supply valve until pressure gauge
maintains 20 kPa (3 psi).
2. Inspect sealed and / or gasketed areas for leaks
by applying a solution of liquid detergent and
water over areas for formation of bubbles, which
indicates leakage.
A19016·A
1. Clean engine (6007) with a suitable solvent to

remove all traces of oil.
Leakage Points
Examine the following areas for oil leakage:


ALL RIGHTS RESERVED
SERVICE PROCEDUR~S (Continued)
Underhood With .Transmission and Flywheel Removed

• Valve cover gaskets (6584) NOTE: Oil leaks at crimped seams in sheet metal
parts and cracks in cast or stamped parts can be
• Intake manifold gaskets (9439) detected when pressurizing the crankcase.
• Head gaskets (6051) NOTE: Light foaming equally around rocker arm cover
• Oil bypass filter (6714) bolts and crankshaft seals is not detrimental and
corrections are not required in such cases.
• Distributor a-ring
NOTE: Air leakage in area around a crankshaft rear oil
• Oil level indicator (dipstick) tube connection
seal does not necessarily indicate a rear seal leak.
• Oil pressure sensor (9278) However, if no other cause can be found for oil
• Cup plugs and / or pipe plugs at end of oil passages leakage, it can be assumed that the crankshaft rear oil
seal is the cause of the oil leakage.
Under Engine, with Vehicle on Hoist
• Crankshaft front seal
• Oil pan gasket (6710)
• Rear main bearing cap parting line
• Oil pan front and rear end seals
• Rear main bearing cap and seals
• Crankshaft front seal (6700)
• Flywheel mounting bolt holes
• Crankshaft rear oil seal (6701)
• Rear cup plugs and / or pipe plugs at the end of oil
• Engine damper keyway (damper to damper passages
bolt / washer interface)
• Upper left-hand transmission to cylinder block bolt
(7.5L only)
Compression Test 4. Install an auxiliary starter switch in starting

circuit. With ignition switch in the OFF position,
Compression Gauge Check and using auxiliary starter switch, crank engine at
1. Make sure oil in crankcase is of the correct least five compression strokes and record
viscosity and at proper level and battery ( 10655) highest reading. Note the approximate number of
is properly charged. Operate vehicle until engine compression strokes required to obtain the
(6007) is at normal operating temperature. Turn highest reading.
off ignition switch (11572), then r.emove all spark 5. Repeat test on each cylinder cranking the engine
plugs (12405). approximately the same number of compression
2. Set throttle plates in wide-open position. strokes.
3. Install a compression gauge such as Rotunda Test Results
Compression Tester 059-R0009 or equivalent in
No. 1 cylinder spark plug opening. The indicated compression pressures are considered
within specification if the lowest reading cylinder is
within 75 percent of the highest. Refer to the following
chart.
COMPRESSION PRESSURE LIMIT CHART
Maximum Minimum Maximum Minimum Maximum Minimum Maximum Minimum
psi psi psi psi psi psi psi psi
134 101 164 123 194 145 224 168
136 102 166 124 196 147 226 169
138 104 168 126 198 148 228 171
140 105 170 127 200 150 230 172
142 107 172 129 202 151 232 174
144 108 174 131 204 153 234 175
146 110 176 132 206 154 236 177
148 111 178 133 208 156 238 178
150 113 180 135 210 157 240 180
152 114 182 136 212 158 242 181
154 115 184 138 214 160 244 183
156 117 186 140 216 162 246 184
(Continued)

ALL RIGHTS RESERVED
SERVICE PROCEDURES (Continued)
COMPRESSION PRESSURE LIMIT CHART (Cont'd)

Maximum Minimum Maximum Minimum Maximum Minimum Maximum Minimum
pel psi pel psi pal pal psi pal
158 118 188 141 218 163 248 186
160 120 190 142 220 165 250 187
162 121 192 144 222 166
Compression Readings - Interpreting While the air pressure is retained in the cylinder, listen
It is recommended the Compression Pressure Limit for the hiss of escaping air. A leak by the intake valve
Chart be used when checking cylinder compression so (6507) will be audible in the throttle body (9E926). A
that the lowest reading number is 75 percent of the leak by the exhaust valve (6505) can be heard at the
highest reading. tail pipe. Leakage past the rings will be audible at the
positive crankcase ventilation (PCV) connection. If air
If one or more cylinders reads low, squirt is passing through a blown gasket to an adjacent
approximately one 1.5 ml (1 tablespoon) of SAE 50 cylinder, the noise will be evident at the spark plug
weight or equivalent engine oil on top of the pistons in hole of the cylinder into which the air is leaking.
the low reading cylinders. Repeat compression Cracks in the cylinder block (6010), or gasket leakage
pressure check on these cylinders. into the cooling system may be detected by a stream
1. If compression improves considerably, piston of bubbles in the radiator (8005).
rings are at fault.
2. If compression does not improve, valves are
sticking or seating poorly.
3. If two adjacent cylinders indicate low
compression pressures and squirting oil on
pistons does not increase compression, cause
may be a cylinder head gasket leak between
cylinders. Engine oil and / or coolant in cylinders
could result from this problem.
Example Readings
For example, check the compression pressures in all
cylinders. If the highest reading obtained was 1351
kPa (196 psi) and the lowest pressure reading was
1069 kPa (155 psi), the engine is within specification
and the compression is considered satisfactory.
Cylinder Leakage Detector ROTUNDA

When a cylinder produces a low reading, the use of PRESSURIZATION
Rotunda Pressurization Kit 014-00705 or equivalent KIT
014-00705 A23452-A
will be helpful in pinpointing the exact cause.
The leakage detector is inserted in the spark plug
hole, the piston is brought up to top dead center on the
compression stroke, and compressed air is admitted. Oil Leak and Valve Guide Seal Test
Once the combustion chamber is pressurized, a The cylinder leakage detector can be used to test for
special gauge will read the percentage of leakage. engine oil leaks and to check the valve seals for
Leakage exceeding 20 percent is considered leakage.
excessive.
1. Plug all crankcase openings except the one used
for connecting the leakage detector.

ALL RIGHTS RESERVED
2. CAUTION: Use extreme caution when

pressurizing crankcase. Applying air
pressure above specified pressure risks
damage to seals, gaskets and core plugs.
Under no circumstances should pressure be
allowed to exceed 27 kPa (4 psi).
Connect the detector to a crankcase opening (oil
level indicator tube (6754) is convenient) and
adjust the air pressure to approximately 20 kPa
(3 psi).
3. Using a solution of liquid soap and water, brush
the solution along the gasket sealing surfaces
and bearing seals. Look for bubbles or foam.
4. Remove the spark plugs (12405) and rotate the A23453-A
engine (6007) slowly with a wrench. Check for
Following are potential gauge readings. Some should
large amounts of air escaping into the cylinders
be considered as normal; others should be
as each intake and exhaust valve opens.
investigated further.
The spark plugs on the leaking cylinders will
probably show deposits of burned oil.
Intake Manifold Vacuum Test

Bring the engine (6007) to normal operating
temperature. Connect Rotunda Vacuum / Pressure
Tester 059-00008 or equivalent to the intake manifold
(9424). Run the engine at the specified idle speed.
The vacuum gauge should read between -51 and -74
kPa (15 and 22 inches of mercury) depending upon the
engine condition and the altitude at which the test is 5 , 7
•
performed. SUBTRACT 5.5 kPa FOR EVERY 500
METERS ABOVE SEA LEVEL. SUBTRACT ONE INCH
FROM THE SPECIFIED READING FOR EVERY 1,000
FEET OF ELEVATION ABOVE SEA LEVEL.
The reading should be quite steady. It may be
necessary to adjust the gauge damper control (where , 10 11 12
used) if the needle is fluttering rapidly. Adjust damper
until needle moves easily without excessive flutter.
Vacuum Gauge Readings - Interpreting
A careful study of the vacuum gauge reading while the
engine is idling will help pinpoint trouble areas. Always
conduct other appropriate tests before arriving at a
final diagnostic decision. Remember that vacuum
gauge readings must be interpreted with care. A10428·A
Most vacuum gauges have a "normal" band indicated 1. NORMAL READING: Needle between -51 and -74
on the gauge face. kPa (15 and 22 in-Hg) and holding steady.
2. NORMAL READING DURING RAPID
ACCELERATION AND DECELERATION: When
engine is rapidly accelerated (dotted needle),
needle will drop to a low (not to zero) reading.
When throttle is suddenly released, the needle
will snap back up to a higher than normal figure.
3. NORMAL FOR HIGH LIFT CAM WITH LARGE
OVERLAP: Needle will register as low as -51 kPa
(15 in-Hg) but will be relatively steady. Some
oscillation is normal.
4. WORN RINGS OR DILUTED OIL: When engine is
accelerated (dotted needle), needle drops to 0
kPa (zero in-Hg). Upon deceleration, needle runs
slightly above 74 kPa (4 in-Hg).
1995 F-150, F-250, F-350, Bronco, F-Super Duty P,owertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
5. STICKING VALVE(S): When the needle (dotted) Oil usage is normally greater during the first 16,000
remains steady at a normal vacuum but km (10,000 miles) of service. As mileage increases,
occasionally flicks (sharp, fast movement) down oil usage generally improves. Cars and light trucks in
and back about 13 kPa (4 in-Hg), one or more normal service should get at least 1448 km (900
valves may be sticking. miles) to 0.9L (1 qt.) after 16,000 km (10,000 miles)
6. BURNED OR WARPED VALVES: A regular, of service.
evenly spaced, downscale flicking of the needle Vehicles used in heavy-duty operation (severe
indicates one or more burned or warped valves. service) may result in greater oil usage. The following
Insufficient hydraulic lash adjuster clearance will are examples of heavy-duty operation:
also cause this action.
• High ambient temperatures
7. POOR VALVE SEATING: A small but regular
downscale flicking can mean one or more valves • Trailer towing applications
are not seating. • Taxi cab applications
8. WORN VALVE GUIDES: When the needle • Police service applications
oscillates (swings back and forth) over a 13 kPa
• Severe loading applications
(4 in-Hg) range at idle speed, the valve guides
(6510) could be worn. As engine sp~d is • Sustained high speed operation
increased, the needle will become steady if the Engines need oil to lubricate the following internal
guides are responsible. components:
9. WEAK VALVE SPRINGS: When the needle
oscillation becomes more violent as engine rpm is • Engine block cylinder walls
increased, weak valve springs (6513) are • Pistons and piston rings
indicated. The reading at idle could be relatively
• Intake and exhaust valve stems
steady.
• Intake and exhaust valve guides
10. LATE VALVE TIMING: A steady but low reading
could be caused by late valve timing. • All internal engine components
11. IGNITION TIMING RETARDING: Retarded ignition When the pistons move downward, a thin film of oil is
timing will produce a steady but low reading. left on the cylinder walls. The thin film of oil is burned
away on the firing stroke during combustion. If an
12. INSUFFICIENT SPARK PLUG GAP: When spark engine burned a drop of oil during each firing stroke, oil
plugs (12405) are gapped too close, a regular, consumption would be about one quart for every mile
small pulsation of the needle can occur. traveled. Fortunately modern engines use much less
13. INTAKE LEAK: A low, steady reading can be oil than this example. However, even efficient engines
caused by an intake manifold or throttle body will use some oil or they would quickly wear out.
gasket (TB gasket)(9E936) leak. Additionally, as the vehicle is operated, some oil is
14. BLOWN HEAD GASKET: A regular drop of drawn into the combustion chambers past the intake
approximately 33~50 kPa (10-15 in-Hg) can be and exhaust valve stem seals and burned.
caused by a blown head gasket (6051) or Many different conditions can affect oil consumption
warped head-to-block mounting surface. rates. A partial list of those conditions includes:
15. RESTRICTED EXHAUST SYSTEM: When the • Operator driving habits
engine is first started and is idled, the reading
may be normal. As the engine rpm is increased, • Ambient temperature
the back-pressure caused by a clogged muffler, • Quality and viscosity of the oil
kinked tail pipe, etc., will cause the needle to
slowly drop to zero. The needle then may slowly • Vehicle load and driving terrain
rise. Excessive exhaust clogging will cause the Operation under certain conditions can create a false
needle to drop to a low point even if the engine is impression of excessive oil consumption. Most
only idled. commonly, this happens when the vehicle has been
operated for repeated short trips at low ambient
When vacuum leaks are indicated, search out and
temperatures. Under these conditions, substantial
correct the condition. Excess air leaking into the
amounts of condensed water and fuel can build up in
system will upset the fuel mixture and cause conditions
the oil. If the vehicle is then run for a significant time at
such as rough idle, missing on acceleration, or burned
highway speeds and / or with heavy loads, much of the
valves. If the leak exists in an accessory unit, such as
accumulated water and fuel can be removed by the
the power brake, the unit will not function correctly.
engine ventilation system. Removing the water and
ALWAYS SERVICE VACUUM LEAKS.
fuel in a relatively short time will often create the
appearance of an excessive consumption rate of the
customer. In this situation, the customer could be
assured that these events are normal for the
Engine Oil Consumption, Excessive conditions noted. The customer might also be advised
The amount of oil an engine (6007) uses will vary with to change oil and filter more frequently, especially prior
the way the vehicle is driven in addition to normal to starting a long trip in cold weather if unduly
engine-to-engine variation. concerned about this condition.

ALL RIGHTS RESERVED
03·00·11 Engine Service, Gasoline 03·00·11
Make sure the selected engine oil meets the b. Run the engine for three minutes (ten minutes
recommended API performance category ··SG" and if cold), then turn engine off. Allow oil to drain
SAE viscosity grade as shown in the Vehicle Owner into the oil pan for an additional five minutes
Guide. It is also important that the engine oil is (vehicle should be on level ground).
changed at the intervals specified for the typical c. Remove oil dipstick and wipe clean. Do not
operating conditions. Refer to Section 00-03. wipe with anything contaminated with silicone
Oil Consumption Test compounds. Reinstall dipstick being sure to
seat the dipstick firmly in the oil level
Use the following procedure to find the source of indicator tube. Remove the dipstick and
excessive internal oil consumption. scribe a mark on the back (unmarked)
1. Determine what the customer considers surface at the indicated oil level. This should
excessive oil consumption to be. Note vehicle be about the same level as the ADD mark on
mileage and the following observations: the face of the dipstick.
a. How many miles are typically driven per quart d. Add 0.9L (1 quart) of oil. Restart the engine
of oil used? and allow it to idle for at least two minutes.
b. How is the vehicle being used (e.g., sustained Shut down and allow oil to drain back for at
high speed operl;ltion, heavy loads, trailer least five minutes. Mark the dipstick using the
towing, high ambient temperature, etc.)? procedure above. This level may range from
slightly below the top of the crc;>sshatched
c. What does the customer expect normal oil area to slightly below the letter F in FULL.
consumption to be?
e. Instruct the customer to drive the vehicle as
2. Verify that the engine has no external oil leak as usual and perform the following steps:
described under Engine Oil Leaks in this section.
3. Verify that the engine has the proper oil level • Check the oil level regularly at intervals of
161 to 241 km (100 to 150 miles).
dipstick (6750) by comparing the part number
stamped on it against the Ford Master Parts • Return to the service facility when the oil
Catalog. Verify that the oil level dipstick and oil level drops below the lower (ADD) mark
level indicator tube (6754) are unmodified and in scribed on the dipstick by the technician.
good condition. Verify that the oil level indicator • In an emergency, add only fulilitres
tube is properly seated in the block or oil pan, and (quarts) of the same oil and note the
the dipstick seats properly in the oil level mileage at which the oil was added.
indicator tube.
f. Check the oil level under the same conditions
4. Verify that the engine is not being run in an as in Steps 5c and 5d, reading the back of
overfilled condition. Check the oil level at least the oil level dipstick where the scribe marks
five minutes after a hot shutdown with the vehicle are located.
parked in a level area. Under no circumstances
should the oil level be above the letter F in the • Measure the distance from the oil level to
word FULL. If a significant overfill is indicated, the upper scribe mark on the oil level
perform Steps 5a through 5d to verify the dipstick and record.
dipstick calibration. If the dipstick calibration
• Measure the distance between the two
checks OK, instruct the customer to avoid scribe marks and record.
overfilling the engine and return the vehicle to
service. To verify the vehicle's actual oil • Divide the first measurement by the
consumption, perform Steps 5e and 5f only after second. Add one to this total for every
the oil level dipstick has been calibrated. quar1 added by the customer as instructed
in Step 5e.
• Divide the distance driven during the oil
test by the result. This quantity is the
KEEP THE OIL IN JHIS RANGE approximate oil consumption rate in miles
~ per quart (MPQ).
ttIJ-----\ g. If the calculated oil consumption rate is
unacceptable, proceed to Step 6.
6. Check PCV valve system. Make sure system is
not plugged.
A17629-D
7. Check for plugged oil drain-back holes in cylinder
5. Perform engine oil consumption test as follows: heads (6049) and cylinder block (6010).
a. Drain engine oil. Remove and replace oil filter.
Using 0.9L (1 quart) less than recommended,
refill crankcase with recommended quality of
oil.
1995 F-150,._F-250, F-350, Bronco, F-Super Duty P,owertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
03·00-12 Engine Service, Gasoline 03·00-12
8. If condition still exists, perform a cylinder • Clogged oil pump screen cover and tube
compression test as described in this section, (6622)
and / or perform a cylinder leak detection test with • Excessive main bearing clearance
Rotunda Pressurization Kit 014-00705 or
equivalent. This can be helpful in determining • Excessive connecting rod bearing clearance
source of oil consumption, i.e., valves, piston
rings, etc.
9. Check valve guides (6510) for excessive guide
clearance. Replace all valve stem / guide seals Valve Train Analysis - Static (Engine Off)
after correct valve guide clearance has been Rocker Arm Cover Removed
verified.
NOTE: Static Valve Train Analysis, with the engine
10. NOTE: After checking for worn parts, if it is (6007) off, is to be performed before Dynamic Valve
determined parts should be replaced, make sure Train Analysis which is performed with the engine
correct replacement parts are used. running.
Worn or damaged internal engine components NOTE: Remove valve cover (6582) as outlined in
can cause excessive oil consumption. Small Section 03-01 A, 03-01 B, or 03-01 C, depending on
deposits of oil on tip of spark plugs (12405) can which engine you are servicing.
be a clue to internal oil consumption. If internal oil
consumption still persists, proceed as follows: Check for damaged and / or severely worn parts,
correct assembly, and use of correct parts by
a. Remove engine from vehicle and place it on proceeding with the static engine analysis.
an engine work stand. Remove intake
manifold(s), cylinder heads, oil pan (6675) Rocker Arm
and oil pump (6600). Refer to procedure in
Section 03-01 A, 03-01 B, and 03-01 C, • Check for loose mounting bolts, studs and nuts.
depending on which engine you are servicing. • Check for plugged oil feed in the rocker arm (6564)
b. Check piston ring clearance, ring gap and or cylinder head (6049).
ring orientation as outlined in this section. Push Rods
Service as required.
• Check for bent push rods (6565) and restriction in
c. Check for excessive bearing clearance as
oil passage.
outlined in this section. Service as required.
11. Perform Step 5 again to confirm oil consumption Valve Springs
concern has been resolved.
• Check for broken or damaged parts.
Oil Pressure Test Valve Spring Retainer and Valve Spring Keys
SPECIAL SERVICE TOOL(S) REQUIRED • Check for proper seating of valve spring retainer
keys (6518) on valve stem and in valve spring
Description Tool Number
retainer (6514).
Engine Oil Pressure Gauge T73L-6600-A
Positive Rotator and Keys
1. Disconnect and remove the oil pressure sensor
(9278) from the engine. • Check for proper seating in the exhaust valve spring
retainer and on valve stem.
2. Connect an Engine Oil Pressure Gauge
T73L-6600-A and Transmission Test Adapter Valves and Cylinder Head
D87C-77000-A, or equivalent, to the oil pressure • Check for signs of improper cylinder head gasket
sender screw port. installation such as the shape of the cylinder head
3. Run the engine until normal operating temperature and block and the shape of the head gasket (6051)
is reached. not matching.
4. Run the engine at 3,000 rpm and record the • Check for signs f cylinder head gasket leakage
gauge reading. such as coolant or oil leaking between cylinder
5. The oil pressure should be: 392-490 kPa (57-71 block and cylinder head.
psi) at 3,000 rpm. • Check for plugged oil drain-back holes.
6. If the pressure is not within specification, check • Check for worn or damaged valve tips.
the following possible sources: • Check for missing or damaged intake and exhaust
• Insufficient oil valve seals.
• Oil leakage • Check valve clearance as outlined in Section
03-01A, 03-01B, or 03-01C, depending on the
• Worn or damaged oil pump engine on which you are servicing.

ALL RIGHTS RESERVED
03-00-13 Engine Service, Gasoline 03-00-1~
• Check installed spring height. This procedure is for checking lift with the camshaft
• Check for missing or worn valve spring seats, if (6250) installed. For checking with camshaft
equipped. removed, refer to service procedures, camshaft, cam
lobe lift in this section.
Check the lift of each lobe in consecutive order and
make a note of the readings.
Valve Train Analysis - Dynamic 1. Remove valve cover (6582) as outlined in Section
NOTE: Static Valve Train Analysis, with the engine off, 03-01 A, 03-01 B, or 03-01 C, depending on which
is to be performed before Dynamic Valve Train engine you are servicing.
Analysis, which is performed with the engine running. 2. Remove rocker arm fulcrum bolts, rocker arm
Start the engine (6007) and, while running at idle, seat (6A528) and rocker arm (6564).
check for proper operation of all parts. Check the 3. Make sure tappet is seated against cam. Install
following: Dial Indicator with Bracketry TOOL-4201-C or
equivalent in such a manner as to have ball
Rocker Arm
socket adapter of indicator on top of valve tappet
Check for plugged oil feed in rocker arm (6564) or (6500) or push rod and in same plane as valve
cylinder head (6049). tappet or push rod movement.
Also inspect for proper overhead valve train
lubrication and examine for plugged oil feed in rocker Typical Engine with Push Rods
arm.
If a condition of insufficient oiling is suspected,
accelerate the engine to 1100 to 1300 rpm with the
transmission in NEUTRAL and the engine at normal
operating temperature. Oil should spurt from the
rocker arm oil holes such that valve tips and rocker
arms are well oiled. If oiling is insufficient for this
condition to occur, check oil passages for blockage.
Push Rods
I Check for bent push rods and restriction in oil
passage.
Check for- proper rotation of push rod (non-roller
tappets). .
Positive Rotator and Valve Spring Keys
Check for proper operation of positive rotator (intake A21124--A
valve only).
Valves and Cylinder Head 4. Remove spark plugs.
Check for plugged oil drain-back holes. 5. NOTE: If checking during engine assembly, turn
crankshaft using a socket or ratchet.
Check for missing or damaged valve stem oil seals or
guide-mounted oil seals. Connect an auxiliary starter switch in starting
circuit. Crank engine with ignition switch in OFF
WARNING: AVOID GETTING OIL ON HOT position. "Bump" crankshaft (6303) over until
EXHAUST MANIFOLDS. valve tappet is on base circle of camshaft lobe.
If a condition of insufficient oiling is suspected, check At this point, valve tappet will be in its lowest
oil passages for blockage, then accelerate the engine position. If checking during engine assembly, turn
to 1200 rpm with the transmission in NEUTRAL and crankshaft using a socket or ratchet.
the engine at normal operating temperature. Oil should 6. Zero dial indicator. Continue to rotate crankshaft
spurt from the rocker arm oil holes such that valve tips slowly until valve tappet is in fully raised position
and rocker arms are well oiled. (highest indicator reading).
7. Compare total lift recorded on indicator with
specifications.
Camshaft Lobe Lift
SPECIAL SERVICE TOOL(S) REQUIRED

Dial Indicator with Bracketry TOOL-4201-C
Hydraulic Tappet Leak-Down Tester TOOL-6500-E

ALL RIGHTS RESERVED
8. NOTE: If lift on any lobe is below specified service A sticking tappet plunger may be caused by dirt,
limits, camshaft and valve tappets operating on chips, or varnish inside the tappet. The sticking can be
worn lobe(s) must be replaced, as well as any corrected by disassembling the valve tappet and
valve tappet showing pitting or having contact removing the dirt, chips or varnish that are causing the
face worn flat or concave. Refer to Hydraulic condition.
Valve Tappets in this section. A tappet check valve that is not functional may be
To check accuracy of original indicator reading, caused by an obstruction (such as dirt or chips)
continue to rotate crankshaft until valve tappet is preventing it from closing when the cam lobe is lifting
once again riding on base circle of camshaft lobe the valve tappet. It may also be caused by a broken
and read indicator. If indicator does not read zero, check valve spring (6513).
repeat Steps 6 through 8. Air bubbles in the lubrication system will prevent the
9. Remove dial indicator and auxiliary starter valve tappet from supporting the valve spring load and
switch. may be caused by too high or too Iowan oil level in the
10. CAUTION: After installing rocker arms, do oil pan, or by air being drawn into the system through a
not rotate crankshaft until valve tappets hole, crack or leaking oil pump inlet tube gasket
have had sufficient time to bleed down. To (6626) on the oil pump screen cover and tube (6622).
do otherwise may cause serious valve If the leak-down time is below the specified time for
damage. Manually bleeding down will reduce used valve tappets, noisy operation may result. If no
waiting time. other cause for noisy valve tappets can be found, the
Install valve cover. leak-down rate should be checked and any outside the
specification should be replaced.
11. Install spark plugs (12405).
Assembled valve tappets can be tested with Hydraulic
Tappet Leak-Down Tester TOOL-6500-E or equivalent
to check the leak-down rate. The leak-down rate
specification is the time in seconds for the plunger to
Hydraulic Valve Tappet move a specified distance of its travel while under a
22.7 kg (50 lb.) load. Test the valve tappets as
SPECIAL SERVICE TOOL(S) REQUIRED follows:
De8crlptlon Tool Number
Hydraulic Tappet Leak-Down Tester TOOL-6500-E
Hydraulic tappet noise may be caused by any of the Camshaft End Play
following conditions:
• Excessive collapsed tappet gap
• Sticking tappet plunger
• Tappet check valve not functioning properly
• Air in lubrication system
• Leak-down rate too rapid
• Excessive valve guide wear
Excessive collapsed tappet gap may be caused by
loose rocker arm fulcrum bolts / nuts, incorrect initial
adjustment, wear of tappet face, push rod, rocker arm
(6564), rocker arm seat (6A528) or valve tip. With
valve tappet (6500) collapsed, check gap between
valve tip and rocker to determine if any other valve
train parts are damaged, worn or out of adjustment.
Replace any worn or damaged parts.

ALL RIGHTS RESERVED
03-00-15 Engine Service, Gasoline 03-0o-1~
1. CAUTION: Prying against the camshaft gear 2. Rotate the crankshaft (6303) so the camshaft
with the val\'e train load on the camshaft can sprocket and crankshaft sprocket timing marks
breaK or damage the gear. Therefore, the lineup.
rocker arm adjusting nuts must be backed 3. Mark the top link(s) of the timing chain.
off, or the rocker arm and shaft assembly
must be loosened sufficiently to free the 4. Have an assistant hold crankshaft with a suitable
camshaft. After checking the camshaft end tool so it cannot turn.
play, resecure valve train components 5. Place a machinists scale above the timing chain
following steps in the specific engine so you can measure its movement.
section.
6. Put a torque wrench and socket on the camshaft
NOTE: For Camshaft End-Play Specifications, sprocket bolt.
refer to Specifications at end of 03-01 A, 03-01 B,
or 03-01 C, depending on which engine you are 7. Apply a maximum of 20 N·m (15 Ib-ft) torque in a
servicing. clockwise direction.
Push camshaft toward rear of engine (6007). 8. Note location of marked link on scale.
Install Dial Indicator with Bracketry TOOL-4201-C 9. Apply a maximum of 20 N·m (15Ib-ft) torque in a
or equivalent so indicator point is on camshaft counterclockwise direction while measuring the
sprocket attaching bolt. amount the marked link moves.
10. Movement should be less than 3.175mm (0.12
inch). If movement is excessive, replace timing
chain as outlined in the appropriate Section
03-018, or 03-01C, depending on which engine
you are servicing.
Timing Gear Backlash, 4.9L

I Description I Tool Number I
I Dial Indicator with Bracketry I TOOL-4201-C I
1. NOTE: Phenolic resin camshaft timing gear
wears faster than hardened steel crankshaft
gear. It is usually sufficient to replace just the
camshaft gear if backlash is excessive.
Remove timing gear cover as outlined in Section
03-01A.
2. Install TOOL-4201-C or equivalent Dial Indicator
A23675-A
with Bracketry on cylinder block as shown in the
2. Zero dial indicator. Pull camshaft forward and following illustration.
release it. Compare dial indicator reading with 3. Check the backlash between the camshaft gear
specifications. If end play is excessive, replace and crankshaft gear at six equally spaced teeth.
camshaft thrust plate. Hold the gear firmly against the block while
3. Remove dial indicator. making the check.
4. After replacing thrust plate, check end play
again. If it is still out of specified range, inspect
camshaft and cylinder block (6010) for excessive
wear.
Timing Chain Deflection (5.0l, 5.al, and

7.5L)
1. Remove engine front cover (6019) as outlined in
Section 03-01 A, 03-01 B, or 03-01 C, depending
on which engine (6007) you are servicing.

ALL RIGHTS RESERVED
)3-00-16 Engine Service, Gasoline 03-00-16
;ERVICE PROCEDURES (Continued)
4. Backlash should be O.1-0.25mm (0.004-0.010

inch). INDICATOR
STYLUS AGAINST
AND PARALLEL
TO CRANKSHAFT
TIMING
GEAR
A21123-A
DIAL INDICATOR
WITH BRACKETRY 7. Zero dial indicator. Push crankshaft (6303)
014-00282
A9799-B forward and note reading on dial.
8. If the end play exceeds the wear limit listed in the
specific engine section, replace the thrust
bearing. Inspect the crankshaft for damage to the
Crankshaft End· Play thrust face before installing the new bearing. If the
end play is less than the minimum limit, inspect
the thrust bearing faces for scratches, burrs,
nicks, or dirt. If the thrust faces are not damaged
Description Tool Number or dirty, they probably were not aligned properly.
Lubricate and install the thrust bearing and align
the faces, following Main Bearing Replacement
After a thrust bearing is replaced it must be aligned as procedure in the appropriate engine section.
follows. If not replaced, go to Step 5. Check the crankshaft end play.
1. Seat the bearings by torquing main caps to
specification. Refer to Section 03-01A, 03-01B,
or 03-Q1C, depending on which engine you are
servicing for engine main bearing cap torque Connecting Rod Side Clearance
specifications.
2. Loosen thrust bearing cap fasteners to relieve
clamp load, but do not disengage cap and Description Tool Number
fasteners. Dial Indicator with Bracketry TOOL-4201-C
3. Firmly pound rear of crank forward with a plastic
hammer to push thrust flange~ forward. 1. Install Rotunda Dial Indicator with Bracketry
TOOL-4201-C or equivalent so that the contact
4. Retorque thrust bearing cap fasteners to point rests against the connecting rod cap.
specifications. Refer to appropriate engine
section. 2. Pull cap toward front of engine (6007) and zero
the dial indicator.
5. Force crankshaft to rear of engine as shown.
3. Push cap toward rear of engine and observe
6. Install Dial Indicator with Bracketry TOOL-4201-C amount of side clearance on dial indicator.
or equivalent so contact point rests against
crankshaft flange and indicator axis is parallel to 4. If side clearance exceeds specification, replace
crankshaft axis. connecting rod and cap. .'
If side clearance is less than specification,
remove rod and cap and inspect for scratches,
burrs, nicks or dirt between crankshaft (6303)
and connecting rod.

ALL RIGHTS RESERVED
Flywheel Runout (Manual Transmission) Cylinder Block

Cleaning and Inspection
SPECIAL SERVICE TOOL(S) REQUIRED If the engine (6007) has been removed and
disassembled, remove all core plugs and pipe plugs.
Description Tool Number Clean the cylinder block (6010) using solvent,
Dial Indicator with Bracketry TOOL-4201-C preferably in a hot tank. Follow all safety and
environmental precautions with regards to the
1. Remove spark plugs (12405). solvents. Make sure all oil and dirt is cleaned from the
cylinder block.
2. Install Dial Indicator with Bracketry TOOL-4201-C
or equivalent so indicator points rest on face of Make sure all oil passageways are clean. A
the flywheel. rifle-cleaning brush is useful for this purpose.
Use a long-thin screwdriver to scrape the bottom of
the water jackets through the openings in the top deck
to make sure all scale and deposits are removed.
Most engines have a "dead spot" at the back of the
block where the coolant has to make a U-turn and
drops any deposits. If the water jackets are not
thoroughly cleaned, overheating will result.
Cylinder Block Distortion
Cylinder block distortion is rare because cylinder
blocks are normalized after casting, but before
machining, to relieve internal stresses from the casting
DIAL INDICATOR process.
STYLUS CONTACTS
FLYWHEEL The most probable cause of cylinder block distortion
APPROXIMATELY would be extreme overheating which would probably
ONE INCH
FROM EDGE
be accompanied by other damage such as scored
bearings or cylinder walls, warped cylinder heads
A21125-A (6049), and possible cylinder block cracks.
3. NOTE: Refer to the Specifications portion of the Cylinder Head Deck Flatness
appropriate engine section in this group for 1. Place a straightedge across the cylinder head
flywheel runout specifications. deck in the six positions shown and measure any
Hold flywheel (6375) and crankshaft (6303) gaps between the straightedge and the deck with
forward or backward as far as possible to a feeler gauge. The deck should be flat within
prevent crankshaft end play from being indicated .076mm (0.003 inch) over 152mm (6 inches) and
as flywheel runout. 0.152mm (0.006 inch) overall.
4. Set indicator dial on zero mark. Turn flywheel one 2. Resurface or replace cylinder block if necessary.
complete revolution while observing total Main Bearing Bore Alignment
indicator reading (TIR). If TIR exceeds
specification, flywheel and ring gear assembly Main bearing bore misalignment may be suspected in
must be replaced. cases of premature bearing wear if one bearing wears
considerably more than the others or bearings wear
5. If clutch face runout exceeds specification, cone-shaped.
remove flywheel and check for burrs between
flywheel and face of crankshaft mounting flange. If bearing misalignment is suspected, perform the
If no burrs exist, check runout of crankshaft following steps:
mounting flange. Replace flywheel or machine 1. Acquire a gauge bar the same diameter as the
crankshaft flywheel mounting face sufficiently to crankshaft journals and which is straight within
true-up the surface. 0.076mm (0.003 inch).
2. Put a thin coating of Prussian Blue or similar die
on gauge bar.
3. Insert good bearings in block.
Service Limit Specifications
4. Insert gauge bar in bearings and rotate one turn.
Service limit specifications are intended to be a guide
only, to be used when overhauling or reconditioning an 5. Remove gauge bar.
engine (6007) or engine component. Determine 6. NOTE: Bearings are not available with oversize
whether a component is suitable for continued service outside diameters to allow line boring.
or should be replaced for extended service while the
engine is disassembled. Inspect bearings. Blue die should be deposited
evenly on all bearings. If die appears on only one
side or bottom of bearing or not at all, cylinder
block is distorted and should be replaced.
ALL RIGHTS RESERVED
Flywheel Housing Deck Flatness • Cylinder block surfaces extending along the length
A concern with the rear deck of the engine would be of the cylinder block, upward from the oil pan rail to
indicated by the following: the cylinder water jacket, but not including
machined areas.
• Frequent replacement of pilot bearing and • Lower rear face of the cylinder block.
transmission input shaft bearing on manual
transmissions vehicles. Also hard shifting into high • Intake manifold casting. Service is not
(not overdrive) gear or jumping out of gear. recommended to the intake manifold exhaust
crossover section, since temperatures can
• Frequent replacement of torque converter seals, exceed the recommended temperature limit of
input shaft seals or bearings, or pump on an 260°C (500°F).
automatic transmission vehicle.
• Cylinder front cover on engines using cast iron
If cylinder block-to-transmission misalignment is material.
suspected, perform the following steps:
• Cylinder head, along the valve cover gasket
1. With crankshaft (6303) installed and engine rear surface.
plate (7007) and flywheel (6375) removed,
attach Rotunda 014-00282 or equivalent Dial The following procedure should be used to service
Indicator with Bracketry to crankshaft. The dial porous areas or sand holes in cast iron.
indicator can be mounted by any method that 1. Clean surface to be serviced by grinding or rotary
holds that extension bar so it does not sag. filing to a clean bright metal surface. Chamfer or
2. Position the dial indicator on the machined flange undercut hole or porosity to a greater depth than
slightly in from the edge. rest of cleaned surface. Solid metal must
surround hole. Openings larger than 6.35mm
3. Zero the dial indicator. (1 / 4 inch) should not be serviced using metallic
4. Because the shape of the flange is irregular, lift plastic. Openings in excess of 6.35mm (1 /4 inch)
the tip of the dial indicator off of the flange. can be drilled, tapped and plugged using common
tools. Clean service area thoroughly. Metallic
5. Rotate the crankshaft to the 12 o'clock position
plastic will not stick to a dirty or oily surface.
and release the dial indicator tip.
2. Mix metallic plastic base and hardener as
6. Take the reading.
directed on container. Stir thoroughly until
7. Lift the pointer off the flange and rotate the uniform.
crankshaft so the dial indicator is just on the
3. Apply service mixture with a suitable clean tool
flange on the right side of the engine.
(putty knife, wood spoon, etc.) forcing epoxy into
8. Release the pointer and take the reading. The hole or porosity.
readings should vary less than plus O.076mm
4. Allow service mixture to harden. This can be
(0.003 in.).
accomplished by two methods. Heat-cure with a
9. Attach Tool-4201-C or equivalent Dial Indicator 250-watt lamp placed 254mm (10 inches) from
with Bracketry to transmission input shaft (7017). serviced surface, or air-dry for 10-12 hours at
10. Position dial indicator on transmission flange just temperatures above 10°C (50°F).
above and inside of hole for left transmission bolt. 5. Sand or grind serviced area to blend with general
11. Zero dial indicator. contour of surrounding surface.
12. Slowly rotate transmission input shaft and take 6. Paint the surface to match the rest of the cylinder
readings from dial indicator at 12 o'clock position block.
and just above rightmost transmission-to-engine
bolt hole.
13. Reading should not vary more than 0.076mm
(0.003 in.). Cylinder Walls, Refinishing
Sand Holes or Porous Engine Castings - Cleaning
Service If the entire engine (6007) has NOT been
Porosity or sand hole(s), which will cause oil seepage disassembled, clean the individual cylinder bore(s)
with a cloth soaked with solvent. Dry with a clean,
or leakage, can occur with modern casting processes.
lint-free cloth.
A complete inspection of engine and transmission
should be made. If the leak is attributed to the porous If the entire engine HAS been disassembled, refer to
condition of the cylinder block or sand hole(s), service Cylinder Block Cleaning in this section.
can be made with Ford Metallic Plastic C6AZ-19554-A
(M3D35-A[ E]) or equivalent. Do not service cracks
with this material. Service with this metallic plastic
must be confined to those cast iron engine component
surfaces where the inner wall surface is not exposed
to engine coolant pressure or oil pressure, for
example:
ALL RIGHTS RESERVED
After any cylinder bore service operation, such as Using a suitable cylinder bore micrometer, measure
honing or deglazing, clean the bore(s) with soap or the cylinder bore(s) in the X and Y directions (90
detergent and water. Then thoroughly rinse the degrees apart) at points A, B, and C. The X direction is
bore(s) with clean water to remove the soap or parallel to the piston pin. The Y direction is
detergent, and wipe the bore(s) dry with a clean perpendicular to the piston pin and is the direction of
lint-free cloth. Finally wipe the bore(s) with a clean piston thrust.
cloth dipped in XO-1 OW30-QSP or equivalent motor oil
meeting Ford specification ESE-M2C153-E.
Inspection
Before removing the piston: A
1. Check the amount of ridge at the top of the bore.
A thick ridge is a sign of considerable wear.
B
2. Look for signs of coolant in the bore, especially
rust on the bore surface indicating possible
leaking head gasket or a crack in the cylinder
bore. c
3. Check the top of the piston for possible oversize.
If oversize pistons have been installed, the
oversize will be stamped in the top of the piston.
A14470-B
After the piston is removed and the bore cleaned:
4. Look for scoring. These are parallel gouges Cylinder Bore Taper
usually on the piston thrust side, that is, at right
angles to the piston pin. If scored, the cylinder will Subtract the micrometer reading from point C direction
have to be refinished. Y from point A direction Y. Also from point C direction
X from point A direction X. Each difference should be
5. Look for cracks. If unsure about a crack, tiny less than o. 127mm (0.005 inch). If taper exceeds this
cracks may be detected by coating the bore with specification, cylinder will have to be refinished.
a mixture of 25 percent kerosene and 75 percent
light engine oil. Wipe the bore dry and
immediately apply a coating of zinc oxide CYLINDER
BORE TAPER
dissolved in wood alcohol. Do not use rubbing
alcohol as a substitute. If cracks are present, the
coating will become discolored at the damaged
area. Replace the cylinder block if it is cracked.
Magnafluxing may also be used.
6. Check for cylinder wall glazing. When refinished,
the cylinder bore is given a slightly rough finish
with a cylinder hone to help seat the new piston
rings. This finish is worn away as the rings and
cylinder bore "mate" and the bore becomes
glassy smooth. If the engine has been run enough
for this to have happened, the cylinder will at
least have to be honed to seat the new rings on
the piston. New rings should be installed when the CYLINDER WALLS
piston is removed and reinstalled because piston
rings are given a special finish by the factory to A14471-A
help them wear-in and seat. In seating, the special
finish is worn off. Reusing piston rings will result in
high oil consumption.
Cylinder Bore
Make sure cylinder bore is clean and dry before
measuring.
ALL RIGHTS RESERVED
Cylinder Out-of-Round
Subtract the reading in direction X (non-thrust) from
direction Y (thrust side) at all points A, B, and C. All PISTON
readings should be less than o. 127mm (0.005 inch). If 6108
out-of-round exceeds this specification, cylinder will
have to be refinished.
FRONT OF
I
E~VL---
o c:::' <:::::J 0 [@]
Jf ~
CYLINDER
BORE
PISTON-TO-CYLINDER
CLEARANCE
A14479·B
A23876-A Cylinder Reboring

1. Reinstall main bearing caps and tighten to
Cylinder Bore Diameter specifications listed in the appropriate Section
1. Measure the diameter of the piston on the thrust 03-01 A, 03-01 B, or 03-01 C, depending on which
side - at right angles to the piston pin - engine you are servicing.
16.5mm (0.650 inch) below the oil ring groove. 2. Using Rotunda 054-00038 or equivalent Boring
Bar, refinish cylinder to a standard oversize
following the tool manufacturer's instructions.
Allow for honing and piston fitting.
Cylinder Wall Honing
Hone the cylinder bore either:
• When reinstalling a piston with new rings.
• To size a rebored cylinder to the piston which will go
into it and prepare the bore surface.
1. Measure the diameter of the piston on the thrust
side - at right angles to the piston pin -
16.5mm 16.5mm (0.650 inch) below the oil ring groove.
(0.650 IN) 2. Measure the cylinder bore diameter at right
OUTER angles to the piston pin at points A, B, and C as
DIAMETER described under cylinder taper.
A14477-B 3. Subtract the piston diameter from the maximum
cylinder bore diameter to determine the maximum
2. Measure the cylinder bore diameter at right amount of material that can be removed.
angles to the piston pin at points A, B, and Cas 4. Hone the cylinder according to the hone
described under cylinder taper. manufacturer's instructions to obtain the proper
3. Subtract the piston diameter from the cylinder bore surface finish of 18-38 RMS.
bore diameters. The difference should not
exceed the maximum clearance allowed in the • Keep the hone moving up and down to achieve
specifications in the appropriate Section 03-01 A. the proper crosshatch pattern.
• Measure frequently to make sure that you do
not remove too much of the cylinder wall
creating excess clearance.
ALL RIGHTS RESERVED
Engine Block Plugs CAUTION: It is imperative to pull the plug into the
machined bore by using a properly designed tool.
SPECIAL SERVICE TOOL(S) REQUIRED Under no circumstances is the plug to be driven
into the bore using a tool that contacts the flange.
Description Tool Number This method will damage the sealing edge and
Impact Slide Hammer T59L-100-B will result In leakage and/or plug blowout.
Impact Slide Hammer T50T-100-A The flanged (trailing) edge must be below the
chamfered edge of the bore to effectively seal the
Removal and Installation plugged bore.
To remove a large core plug, drill a 12.70mm (1/2
inch) hole in the center of the plug and remove with an
Impact Slide Hammer T59L-100-B or T50T-100-A or
pry it out with a large drift punch. On a small core plug,
drill a 6.35mm (1 /4 inch) hole in the center of the plug
and pry it out with a small pin punch. Clean and inspect
the plug bore.
Prior to installing a core plug, the plug bore should be
inspected for any damage that would interfere with the J(J(J(J(X)(XJ(XXJ(J(XXXXX)(XXXXXX)()()()()()(W',O(WW)(
proper sealing of the plug. If the bore is damaged, it

will be necessary to true the surface by boring for the
next specified oversize plug.
Oversize plugs are identified by the OS stamped in the
flat located on the cup side of the plug.
A
Coat the plug and / or bore lightly with an oil-resistant
(oil galley) Stud and Bearing Mount EOAZ-19554-BA
or equivalent meeting Ford specification
WSK-M2G349-A 1, or Threadlock@ 262
E2FZ-19554-B or equivalent meeting Ford
specification WSK-M2G351-A6, and install it following
the procedure for cup-type or expansion-type below:
Cup-Type
Cup-type core plugs are installed with the flanged
edge outward. The maximum diameter of this plug is
located at the outer edge of the flange. The flange on
cup-type plugs flare outward with the largest diameter
of the outer (sealing) edge. A3217-D
Expansion-Type Part
Expansion-type core plugs are installed with the flange Item Number Description
edge inward. The maximum diameter of this plug is 1 - Cup-Type Core Plug
located at the base of the flange with the flange flaring Replacer Tool - Typical
inward. 2 6026 Engine Block Plug -
CAUTION: It is imperative to push or drive the Cup-Type
plug into the machined bore using a properly 3 - Expansion-Type Core Plug
designed tool. Under no circumstances is the Replacer Tool - Typical
plug to be driven using a tool that contacts the 4 6026 Engine Block Plug -
crowned portion of the plug. This method will Expansion-Type
expand the plug prior to installation and may A - Sealing Edge Before
damage the plug and/or plug bore. Installation
When installed, the trailing (maximum) diameter must
be below the chamfered edge of the bore to effectively
seal the plugged bore.
Crankshaft Main and Connecting Rod
If the core plug replacing tool has a depth seating
surface, do not seat the tool against a Bearings
non-machined (casting) surface. Cleaning
NOTE: Do not scrape gum or varnish deposits from
the bearing shells.
Bearings that are to be reused should be identified so
they can be installed in their original locations.

ALL RIGHTS RESERVED
CIE;lan the bearing inserts and caps thoroughly in Crankshaft Main or Connecting Rod Bearings
solvent, and dry them with compressed air. - Fitting
Inspection Plastigage@ Method
Inspect each bearing carefully. Bearings that have a 1. Clean crankshaft journals. Inspect journals and
scored, chipped or worn surface should be replaced. thrust faces for nicks, burrs or roughness that
Typical examples of unsatisfactory bearings and their would cause premature bearing wear. When
causes are shown in the illustration. The copper lead replacing standard bearings with new
bearing base may be visible through the bearing bearings, it is good practice to fit bearing to
overlay. If the base showing is less than 20 percent of minimum specified clearance. If desired
the total area, the bearing is not excessively worn. It is clearance cannot be obtained with a standard
not necessary t9 replace the bearing if the bearing bearing, try a 0.050mm (0.002-inch) undersize
clearance is within recommended limits. Check the bearing set to obtain proper clearance.
clearance of bearings that appear to be satisfactory
with Plastigage@ as described in this section. 2. CAUTION: Do not position jack under
crankshaft pulley. Crankshaft post damage
will result.
If fitting main bearing in-vehicle, position a jack
under counterweight adjoining bearing which is
being checked. Support crankshaft (6303) with
jack so its weight will not compress Plastigage@
and provide an erroneous reading.
3. Place a piece of Plastigage@ 081 L-6002-8 or
equivalent on bearing surface across full width of
bearing cup and about 6.35mm (1 /4 inch) off
center.
A23338-A A23339-A
Part Part
1 6333 Connecting Rod Bearing 1 081 L-6002-B Plastigage@
A - Fatigue Failure - Craters or 2 - Plastigage@ Scale
Pockets (Part of 081 L-6002-B)
B - Improper Seating - Bright A - Check Width of Plastigage@
(Polished) Sections
B - Location of Plastigage@
C - Dirt Scratching, Imbedding Prior to Tightening
0 - Overlay Wiped Out - Lack
of Oil or Improper Clearance 4. Install cap and tighten bolts to specification. Do
E - Hourglass - Overlay Gone not turn crankshaft while Plastigage @is in place.
from Edges
5. Remove cap. Using Plastigage@ scale, check
F - Radius Ride width of Plastigage@ at widest point to get
minimum clearance. Check at narrowest point to
get maximum clearance. Difference between
reading is taper of journals.

ALL RIGHTS RESERVED
03·00-23 Engine Service, Gasoline 03·00-23
6. If bearing clearance exceeds the specified limits, 7. After bearing has been fitted and cleaned, apply a
try using one of the various combinations of light coat of engine oil to journal and bearings.
undersize bearings as directed by the Install bearing cap. Tighten cap bolts to
accompanying table. Use of any other bearing specification.
combination is not recommended. Bearing S. Repeat procedure for remaining bearings that
clearance must be within specified limits. Refer to require replacement.
Specifications in Section 03-o1A, 03-01B, or
03-01 C, depending on which engine you are 9. Refer to Crankshaft End Play procedure in this
servicing, for main and connecting rod bearing section for proper thrust bearing seating.
clearance limits. If use of these bearing
combinations does not bring clearance to the
desired limits, refinish the crank journal to a
standard undersize, and use the appropriate
undersize bearing.
I Use This Bearing Size

For This Amount
Of Bearing'
Clearance Excess (Upper Bearing) (Lower BearlnO)
mm Inch mm Inch mm Inch
0.0-0.013 0.0-0.0005 0.025 0.001 U.S. Standard Standard
0.013-0.026 0.0005-0.0010 0.025 0.001 U.S. 0.025 0.001 U.S.
0.026-0.039 0.0010-0.0015 0.050 0.002 U.S. 0.025 0.001 U.S.
0.039-0.052 0.0015-0.0020 0.050 0.002 U.S. 0.050 0.002 U.S.
Bore Gauge Method Crankshaft

1. Install bearings in the cylinder block (6010) and Cleaning
bearing caps.
CAUTION: Handle the crankshaft (6303) with
2. Install crankshaft and tighten main bearing cap care to avoid possible damage to the finished
bolts to the specified torque as outlined in the surfaces.
appropriate Section 03-01 A, 03-01 B, or 03-01 C
depending on which engine (6007) you are Clean the crankshaft with solvent, then blowout all oil
servicing. passages with compressed air.
3. Remove bearing caps and crankshaft. Inspection
4. Reinstall bearing caps with bearings still installed Measure the diameter of each journal in at least four
in cylinder block and caps. places to determine an out-of-round, taper or
undersize condition. For specifications, refer to
5. Tighten bearing cap bolts to torque specified in Section 03-01A, 03-o1B, or 03-01C, depending on
appropriate Section 03-o1A, 03-01B, or 03-01C, which engine you are servicing.
depending on Which engine you are servicing.
On an engine with a manual transmission, check the fit
6. Using micrometer, measure main bearing journals of the pilot bearing in the bore of the crankshaft. A
as outlined in this section. needle roller bearing and adapter assembly is used as
7. Using bore gauge, measure the inside diameter of a pilot bearing. It is press fit directly into the engine
each bearing assembly. It may be necessary to crankshaft and should not be loose. Inspect the inner
measure the outer bearings first, then remove surface of the pilot bearing for wear or a bell-mouth
those caps and measure the inner bearings. condition. Check the inside diameter of the pilot
bearing to see if it is worn or damaged. The bearing
S. Subtract the maximum measurement for each
and adapter assembly cannot be serviced separately.
journal from the minimum measurement of each
The pilot bearing can only be installed with the seal
bearing to determine the minimum oil clearance.
end of the bearing facing the transmission. The
Allowable clearances are as follows: bearing and seal are pregreased and do not require
additional lubrication.
• 4.9L 0.023-0.069mm (0.0009-0.0027 inch)
NOTE: A new bearing must be installed whenever a
• 5.0L 0.01S-0.060mm (0.0007-0.0024 inch) bearing is removed.
• 5.SL and 5.SL Lightning 0.046-0.063mm Inspect the pilot bearing, when used, for roughness,
(0.000S-0.0025 inch) evidence of overheating or loss of lubricant. Replace if
• 7.5L 0.046-0.063mm (0.000S-o.0024 inch) any of these conditions are found.

ALL RIGHTS RESERVED
Crankshaft Runout After refinishing the journals, chamfer the oil holes.
1. NOTE: Check crankshaft journals for out-of-round Polish the journals with a No. 500 grit polishing cloth
before checking for runout, or an out-of-round and engine oil (crocus cloth may also be used as a
condition on the center journal could be confused polishing agent) to obtain a smooth finish.
for an excess runout condition. Crankshaft Sprocket or Gear
Set V-blocks on surface plate and set crankshaft Inspect crankshaft sprocket or gear for chipped,
on V-blocks supported on the outer two main broken, or excessively worn teeth. If necessary,
bearing journals. remove and replace as outlined in the appropriate
2. Set up TOOL-4201-C or equivalent Dial Indicator Section 03-01 A, 03-01 B, or 03-01 C, depending on
with Bracketry or equivalent to measure runout which engine you are servicing.
on center main bearing journal.
3. Zero dial indicator.
4. Slowly rotate crankshaft one revolution, Pistons, Piston Pins and Piston Rings
recording highest and lowest readings.
5. Crankshaft runout should not exceed 0.03mm SPECIAL SERVICE TOOL(S) REQUIRED
(0.0012 in.). If crankshaft runout is excessive,
replace crankshaft.
Engine Cylinder Hone Set T73L-6011-A
MAGNETIC
BASE Cleaning
DIAL
INDICATOR • Clean piston using suitable solvent.
D78P-4201-B • A putty knife or scraper may be used to help clean
carbon off of the top of the piston.
• Do not use a power wire brush to clean the piston
skirt, crown, or piston ring grooves as it will remove
metal.
• If using a ring groove scraper, be careful not to
remove metal from the piston ring lands.
Inspection
Inspect for:
• Hole or crack in top of piston caused by preignition
V-BLOCKS or foreign object damage.
A16693-B
• Excess wear in ring lands indicated by visible steps
Crankshaft End Play worn in ring lands.
Refer to crankshaft end play elsewhere in this section. • Scoring or gouges on piston skirt or crown.
Crankshaft must be installed in block with the bearings
• Looseness between piston and piston pin.
that will be used, but without connecting rods (6200),
pistons, or flywheel (6375) installed to check end play. Pistons - Fitting
Journals Refinishing NOTE: There are two procedures for piston fitting.
One is used when the original standard-size bore
Dress minor imperfections such as scores, nicks or
shows little wear and can be cleaned up. The second
burrs with an oil stone.
is used after the cylinder has been rebored.
If journals are severely marred or exceed service limits
for wear, taper, or out of round, they should be Original Bore
refinished to size for the next undersize crankshaft 1. Measure cylinder bore as outlined in this section
main bearing. under Cylinder Bore Measuring. If cylinder bore is
Follow crankshaft lathe manufacturer's instructions for not damaged and wear, taper, and out-of-round
refinishing cranksh~ft. are within specifications listed in the appropriate
Section 03-01 A, 03-01 B, or 03-01 C, depending
If the journals will not clean up to less than the on which engine you are servicing, then the
maximum undersize bearing available, replace the cylinder bore may be cleaned up and reboring is
crankshaft. unnecessary.
Always reproduce the same journal shoulder radius 2. Hone cylinder, if necessary, to restore a proper
that existed originally. Too small a radius will result in crosshatch pattern so new rings can seat.
fatigue failure of the crankshaft. Too large a radius will Remove as little of the cylinder wall as possible.
result in bearing failure due to radius ride of the
crankshaft bearing. • If clearance exceeds specifications, the piston
will have to be replaced.

ALL RIGHTS RESERVED
03·00-25 Engine Service, Gasoline 03·00·25
• If clearance is within specifications, proceed to Piston Rings - Fitting

assemble and install the piston as outlined in Do nat reinstall used piston rings. A special break-in
Section 03-01A, 03-01B, or 03-01C, finish, and sometimes an anti-scuff coating, is given to
depending on which engine you are servicing. new piston rings by the factory. The purpose of the
Red and blue select fit pistons are available for special finish is to help the new piston rings and
select fitting a standard size bore if only a slight cylinder bore mate properly. The special finish, like the
cleanup was required. A .076mm (.003 inch) crosshatching on the cylinder bore, wears off during
oversize piston is available if greater cleanup was break-in. The special finish will be already worn off
required. Refer to Master Parts Catalogue. used rings so they probably will not seat properly. For
3. Subtract from cylinder bore dimension this reason attempting to reuse piston rings could lead
determined earlier. If within specifications in the to excess oil consumption and possible cylinder
appropriate Section 03-01 A, 03-01 B, or 03-01 C . scoring.
depending on which engine you are servicing, 1. Insert each piston ring backwards in the piston
proceed to install the piston as outlined in that ring groove into which it will be installed.
section. If not, try the other color piston. If neither 2. Measure the clearance between the ring and
of the standard bore "color" pistons can be groove (side clearance) with a feeler gauge and
brought within the maximum clearance, proceed check against the side clearance specifications in
to fit the O.076mm (0.003 inch) piston. the appropriate Section 03-01 A, 03-01 B, or
After Reboring 03-01 C, depending on which engine you are
servicing.
1. NOTE: When reboring cylinder, leave bore
o. 13mm (0.005 inch) undersize to allow for
honing and fitting piston.
Measure the diameter of the oversize piston on
the thrust side-at right angles to the piston pin
16.5mm (0.650 inch) below the oil ring groove.
2. Remeasure the cylinder bore as outlined in this
section under Cylinder Bore Measuring.
3. Subtract the piston diameter from the cylinder
bore diameter to determine how much material
must be removed during honing to establish
correct piston-to-cylinder bore clearance in
Specifications in appropriate Section 03-01 A,
03-01 B, or 03-01 C, depending on which engine
you are servicing. NEW
4. Using T73L-6011-A Engine Cylinder Hone Set, PISTON
hone the cylinder bore to bring the RING
6149
piston-to-cylinder clearance within specifications. A14480-B
• Take frequent measurements to assure you do 3. Insert the ring in the cylinder bore.
not remove too much metal from the cylinder 4. Using the piston, without rings, turned upside
bore. down, press the ring down to the center of the
• Move hone up and down to attain proper bore.
crosshatch pattern and prevent tapering
cylinder bore.
PISTON
5. Once proper fit and crosshatch pattern is
achieved, proceed to assemble and install piston
as outlined in appropriate Section 03-01 A,
03-o1B, or 03-01C, depending on which engine
you are servicing. If the entire engine is being
rebuilt, make sure piston and rod assemblies are
marked so each piston is installed in the bore to
which it was fitted.
A238n-A
5. Make sure that the ring is "square" in the bore.

ALL RIGHTS RESERVED
6. Check the piston ring end gap specification in the

appropriate Section 03-01 A, 03-01 B, or 03-01 C,
depending on which engine you are servicing.
Using a feeler gauge check the piston ring end
gap.
C
PISTON
PISTON 6108
RING A2811-C
6149 A14712-B
10. Using a feeler gauge, recheck piston ring side
7. If the ring gap is too small, the ring will have to be clearance.
filed until the end gap is within specifications. The
use of a ring filing block helps to make sure that
the ring ends are filed square. FEELER
GAUGE
FILING BLOCK
FILE
PISTON
RING
6148
A23879-A
11. Continue with engine assembly as outlined in the
A23878-A appropriate Section 03-01 A, 03-01 B, or 03-01 C,
depending on which engine you are servicing.
8. CAUTION: Install the piston rings after the
piston has been installed on the connecting Piston and Piston Pin Fit
rod. Since the piston may be supported by NOTE: New pistons come with fitted pins and should
the crown during this operation, the rings not require refitting unless the connecting rod bore is
could be damaged. oversize.
CAUTION: Use a piston ring expander to The Ford 4.9L, 5.0L, 5.8L, and 7.5L gasoline engines
install the piston rings. Attempting to wind all use piston pins which press into the connecting rod.
them on by hand may put a deep scratch in The piston pivots on the pin. There is no connecting
the piston or break the ring. rod bushing and an interference fit between the piston
Using a piston ring expander, install the piston pin and the connecting rod (6200).
rings starting with the oil control rings. Make sure Refer to Section 03-01A, 03-018, or 03-01C,
rings are installed right side up. Refer to depending on which engine you are servicing, for
instructions with the ring set. specifications and assembly instructions.
9. Rotate the rings so the end gaps are NOT lined up 1. Clean and inspect the connecting rod as outlined
but are spaced properly as shown. in this section.

ALL RIGHTS RESERVED
2. Clean and inspect the piston and pin as outlined in Twisted connecting rods can create an identifiable
this section. piston skirt wear pattern, but badly twisted rods will
3. Using a suitable micrometer, measure the piston disturb the action of the entire piston, rings, and
pin both places where the piston pivots and in the connecting rod assembly and may be the cause of
center where it is pressed into the connecting excessive oil consumption.
rod. Check the connecting rods for bend or twist on a
4. Using a suitable set of plug gauges, measure the suitable alignment fixture. Follow the instructions of
upper bore of the connecting rod. An interference the fixture manufacturer. If the bend and / or twist
fit is required. If the bore is oversize it will be exceeds specification, the connecting rod must be
necessary to install an oversize piston pin. It is replaced.
not necessary to rebore or ream the connecting Inspect the connecting rods for signs of fractures and
rod. the rod bearing bores for out-of-round and taper. If the
5. If the pin-to-rod fit is OK, measure the piston pin bore exceeds the recommended limits and / or if the
bores in the piston. connecting rod is fractured, it should be replaced.
6. Subtract the piston pin size from the piston pin Piston Pin Clearance
bore sizes. Pin-to-piston clearance is listed in the Refer to Piston and Piston Pin Fit in this section.
specifications in Section 03-01 A, 03-01 B, or
03-01C, depending on which engine you are
servicing.
If clearance is excessive it will be necessary to fit Camshaft
an oversize pin.
7. To fit an oversize piston pin because either the SPECIAL SERVICE TOOL(S) REQUIRED
pin-to-connecting rod or pin-to-piston clearance Description Tool Number
was excessive:
• Obtain an appropriate oversize piston pin.
• Hone or ream the piston pin bores in the piston Cleaning
to obtain the correct clearance. 1. If not done as part of engine disassembly, remove
• It is not necessary to hone or ream the camshaft center bearing (6262) or gear from
connecting rod piston pin bore oversize. camshaft (6250) and camshaft from engine as
outlined in Section 03-01A, 03-01B, or 03-01C,
8. Once pin, connecting rod, and piston are depending on which engine you are servicing.
correctly sized to each other, assemble as
outlined in Section 03-01A, 03-01B, or 03-01C, 2. Clean the camshaft in an appropriate solvent and
depending on which engine you are servicing. wipe it dry.
3. Remove light scuffs, scores, or nicks from the
camshaft machined surfaces with an oil stone.
Inspection
Connecting Rods
Inspect the camshaft journals and lobes for scoring
Cleaning and signs of abnormal wear.
Remove the connecting rod bearings (6211) from the Lobe pitting, except in the general area of the lobe toe,
rod and cap. Identify each bearing location if they are is not detrimental to the operation of the camshaft.
to be used again. Clean the connecting rod (6200) in The camshaft should not be replaced unless lobe lift
solvent, including the rod bore and the back of the loss has exceeded the specifications or pitting has
inserts. Do not use a caustic cleaning solution. occurred in the lobe lift area. Refer to Cam Lobes in
Blowout all passages with compressed air. this section.
Inspection Camshaft Bearings
The connecting rod bearings and related parts should 1. If engine (6007) has not been disassembled and
be carefully inspected and checked for conformance cleaned, wipe bearing bore clean with a clean rag
to specifications. For specifications, refer to the and solvent. Dry with a clean rag.
appropriate engine section. Various forms of engine
wear caused by these parts can be readily identified. 2. Inspect for scoring and visible wear. Inspect if
Babbitt has been worn away to base. If visibly
A shiny surface on either pin boss inside of the piston worn or damaged, bearings will have to be
usually indicates that a connecting rod is bent. replaced. If one of the center bearings is worn
Abnormal connecting rod bearing wear can be caused significantly more than the end bearings, check
by either a bent connecting rod, worn or damaged camshaft for excessive runout.
piston pin, or a tapered connecting rod bore. 3. Using suitable bore gauge or inside micrometer,
measure each bearing twice, 90 degrees apart,
to determine bearing size and out of round.

ALL RIGHTS RESERVED
4. Check results against specifications in

appropriate Section 03-01A, 03-o1B, or 03-01C,
depending on which engine you are servicing. If
bearings are out of specifications, they will have
to be replaced. Check camshaft journals before
replacing bearings to determine if undersize
bearings are required.
5. If necessary, replace bearings as outlined in
Section 03-01A, 03-o1B, or 03-o1C, depending
on which engine you are servicing.
Camshaft Bearing Journals
1. Measure each journal twice, 90 degrees apart, to
determine journal wear, size, and out of round. A14453·B
2. Check measurements against specifications in
Section 03-01A, 03-018, or 03-01C, depending Cam Lobe Lift (Camshaft Removed)
on which engine you are servicing. There are two ways of measuring cam lobe lift with the
3. If journals are excessively out of round or worn, camshaft removed, with a vernier caliper camshaft or
regrind to a standard undersize. Refer to Master on a lathe or cam grinder with a dial indicator. The
Parts Catalogue. If journals are too worn to be second method is more accurate.
refinished to an available undersize, camshaft will
have to be replaced.
With Calipers
1. Inspect camshaft as outlined in this section.
Camshaft Journal Oil Clearance
2. Measure the distance of each cam at the major
1. Measure camshaft bearings and camshaft diameter.
bearing journals as outlined in this section.
3. Measure the distance of each cam at the minor
2. Subtraot size of journal from the size of its diameter.
bearing.
4. For each cam, subtract the minor diameter from
3. Check clearance against specifications in Section the major diameter. The result for each lobe is the
03-01A, 03-01B, or 03-01C, depending on which lobe lift.
engine you are servicing.
5. Check the lobe lift for each cam against the
4. If clearance is excessive, but camshaft journals specifications in Section 03-01 A, 03-01 B, or
are within specifications, simply install new 03-01C, depending on which engine you are
bearings. If both bearings and journals are worn, servicing.
turn camshaft journals to a standard undersize
and install new bearings. 6. If any cam is worn excessively, the camshaft and
tappets will have to be replaced.
Camshaft Runout
NOTE: Check camshaft journals for out of round
before checking for runout, or an out of round condition
on the center journal could be confused for an excess
runout condition.
1. Set suitable V-blocks on surface plate. Support
outer camshaft journals on V-blocks.
DIMENSION A MINUS
2. Set up Rotunda 014-00282 or equivalent Dial DIMENSION B EaUALS
Indicator with Bracketry to check center bearing THE CAM LOBE LIFT
journal.
3. Zero dial indicator. B ,...,.---+---~
4. Slowly rotate camshaft to determine overall
runout. If runout exceeds 0.03mm (0.0012 in.),
replace camshaft.
A
A21328-A
On a Camshaft Grinder or Lathe

1. Clean and inspect the camshaft as outlined in this
section.
2. Install the camshaft on the lathe or camshaft
grinder centers.

ALL RIGHTS RESERVED
3. Position the dial indicator which comes with the Flat Tappet Wear
machine at the heel of the cam which you are
going to check. ACCEPTABLE UNACCEPTABLE
4. Zero the dial indicator. (CONTACT FACE

CONVEX AND SMOOTH)
I
5. Slowly turn the camshaft until the point of the dial
indicator is on the tip of the cam. ,.,. --:L........... I Ftt
T CONCAVE
I
I
6. Read the dial indicator. This is your cam lobe lift. ...._L-~
7. Check the lobe lift against the specifications in

Section 03-01A, 03-01B, or 03-01C.lf any cam is II II I II
I;
excessively worn, the camshaft and tappets will
II I II :11
have to be replaced. II
Camshaft Sprocket or Gear
Inspect camshaft sprocket or gear for worn or broken A429~B
teeth. If a gear (4.9L), check backlash as outlined in

this section. If necessary remove as outlined in Section
03-01A, 03-01B, or 03-01C, depending on which
engine you are servicing. Leak-Down Testing
Remove tappets as outlined in Section 03-01 A,
03-01 B, or 03-01 C depending on which engine you are
servicing.
Hydraulic Valve Tappets
1. NOTE: Do not mix parts from different valve
Valve tappets (6500) should be kept in proper
tappets (6500). Parts are select-fitted and are
sequence so that they can be installed in their original
not interchangeable.
position. Inspect and test each valve tappet
separately so as not to intermix. If any part of the NOTE: Tappets cannot be checked with engine
valve tappet needs replacing, replace the entire oil in them. Only testing fluid can be used.
assembly. Disassemble and clean valve tappet to remove all
Cleaning traces of engine oil.
Thoroughly clean all the parts in clean solvent and 2. Place valve tappet in tester, with plunger facing
wipe them with a clean, lint-free cloth. upward. Pour hydraulic tester fluid into cup to a
level that will cover tappet assembly. The fluid
Inspection can be purchased from manufacturer of tester.
Inspect the parts and discard the entire valve tappet if Using kerosene or any other fluid will not provide
any part shows pitting, scoring or excessive wear. an accurate test.
Replace the entire assembly if the plunger is not free in 3. Place a 7.94mm (51 16-inch) steel ball provided
the body. The plunger should drop to the bottom of the with tester in plunger cap.
body by its own weight when assembled dry and
check ball assembly removed.
Assemble the valve tappet and check for freeness of
operation by pressing down on the plunger. The valve
tappets can also be checked with a hydraulic tester to
test the leak-down rate. Follow the instructions of the
test unit manufacturer or Valve Train
Analysis-Dynamic, Hydraulic Valve Tappet Leak Down
Test in this section.
A8507·B

ALL RIGHTS RESERVED
4. Adjust length of ram so that pointer is 1.59mm Cleaning

(1 / 16 inch) below starting mark when ram 1. If not removed as part of engine disassembly,
contracts tappet plunger, to facilitate timing as remove oil pump (6600) as outlined in Section
pointer passes Start liming mark. 03-o1A, 03-018, or 03-o1C, depending on which
engine you are servicing.
2. If not done already, lift out oil pump intermediate
shaft (6A618).
3. Remove two screws and oil pump screen cover
and tube (6622), and oil pump inlet tube gasket
(6626).
4. Remove the cover attaching bolts and the cover.
ADJUSTING NUT
5. Remove the inner rotor and shaft assembly, then
HYDRAULIC TAPPET
LEAKOOWN tESTER
remove the outer race.
TOOL-6500-E 6. Drill a small hole and insert a self-threading sheet
metal screw of the proper diameter into the oil
pressure relief valve chamber cap and pull the
A8508-8
cap out of the chamber. Remove the spring and
plunger.
Use center mark on pointer scale as Stop liming
point instead of original Stop liming mark at top
of scale.
5. Work tappet plunger up and down until tappet fills
with fluid and all traces of air bubbles have
disappeared.
6. Allow ram and weight to force tappet plunger
downward. Measure exact time it takes for
pointer to travel from Start liming to Stop liming
marks of tester.
7. NOTE: Refer to the Specifications portion of
Section 03-01 A, 03-01 B, or 03-01 C for hydraulic
lifter leak-down rates.
A valve tappet that is satisfactory must have a 9
leak-down rate (time in seconds) within minimum
and maximum limits specified. 10
8. Remove fluid from cup and bleed fluid from tappet
by working plunger up and down. This step will
aid in depressing tappet plungers when checking
valve clearance. ~ 12
9. If a tappet is not within specifications: A23880-A
• Remove camshaft as outlined in Section
03-01A, 03-018, or 03-01C, depending on Part
which engine you are servicing. Item Number Description
• Inspect camshaft and check condition and 1 - Bolt (Part of 6600)
Cam Lobe Lift as outlined in this section. 2 6622 Oil Pump Screen Cover and
• Replace defective tappets with new ones. It is Tube
not necessary to disassemble and clean new 3 6626 Oil Pump Inlet Tube Gasket
tappets to test them since they are shipped 4 - Plug (Part of 6600)
with testing fluid. 5 - Oil Relief Valve Spring
(Part of 6600)
6 - Oil Relief Valve Plunger
(Part of 6600)
Oil Pump 7 - Oil Pump Body
(Part of 6600)
SPECIAL SERVICE TOOL(S) REQUIRED 8 - Outer Rotor
(Part of 6600)
Description Tool Number 9 - Identification Mark
(Part of 6600)
Valve / Clutch Spring Tester TOOL-6513-00
10 - Inner Rotor (Part of 6600)
(Continued)

ALL RIGHTS RESERVED
Tooth Tip Clearance

Part
Item 1. With inner and outer rotor installed, use feeler
Number Description
gauge to measure clearance between inner and
11 - Identification Mark outer rotor at tip of inner rotor furthest from outer
(Part of 6600) rotor.
12 - Cover Plate (Part of 6600)
2. Check against specifications in Section 03-01A,
13 - Bolt (Part of 6600)
you are servicing.
(10-15 Lb-Ft)
3. If clearance excessive, replace oil pump.
7. Clean all parts in solvent and dry them thoroughly
with compressed air. Use a brush to clean the
inside of the pump housing and pressure relief
valve chamber. Make sure all dirt and metal
particles are removed.
Inspection
1. Look for deep scoring in cover. Light concentric
scratches only indicate that the pump has been
used and are acceptable.If cover is deeply
scored, replace oil pump.
2. Look for scoring or wear on the shaft. If severely
scored, replace.
3. Inspect the rotor for burrs or score marks.
4. Remove minor imperfections from parts with an
oil stone.
Outer Rotor-to-Pump Body Clearance
Rotor Clearance 1. Using feeler gauge measure clearance between
1. Using a straightedge and feeler gauge, make outer rotor (race) and housing.
sure inside of cover is flat. If a 0.038mm (0.0015
2. Check against specifications in Section 03-01A,
inch) feeler gauge can go under straightedge, oil
03-01B,or03-01C.
pump should be replaced.
3. If clearance is excessive, replace oil pump.
2. Insert the inner and outer rotor into the housing.
3. Place a straightedge over the rotor assembly and
the housing.
4. Measure the clearance between the straightedge Pressure Regulator Valve Inspection
and the inner rotor, then the outer rotor. Inspect valve plunger for scoring and free operation.
Clearance must not exceed 0.10mm (0.004 Light scratches may be removed with a crocus cloth.
inch).
If clearance is excessive, replace oil pump. Pressure Regulator Valve Spring Inspection
1. Inspect for breaks, cracks, tilting, and collapsed
coils.
2. Using TOOL-6513-DD or equivalent, check valve
spring tension. Check against specifications in
Section 03-01A, 03-01B, or 03-01C, depending
on which engine you are servicing. A weak spring
must be replaced.
Pressure Regulator Valve-to-Housing

Clearance
1. Using plug gauge, measure regulator valve bore.
2. Using micrometer, measure outside of plunger.
3. Subtract plunger diameter from bore size and
check against specifications in Section 03-01 A,
you are servicing. If clearance is excessive,
replace oil pump (6600).
1995 F-150, F-250, F-350, Bronco, F-Super puty Powertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
Oil Pan 1. CAUTION: The cylinder head must be

removed from engine (6007) before
Cleaning installing a taperset. The service procedure
Scrape any dirt or metal particles from the inside of includes a thread cutting process which
the oil pan (6675). Scrape all old gasket material from produces metal chips. Performing this
the gasket surface. Wash the pan in a solvent and dry procedure while the cylinder head is on the
it thoroughly. Make sure all foreign particles are engine will cause metal chips to fall into the
removed. cylinder. Once in the cylinder, these chips
can damage the cylinder wall when the
Inspection engine is started.
Check the oil pan for cracks, holes or damaged drain
plug threads. Check the gasket surface for damage
caused by over-tightened bolts. Replace with a new oil
pan if repairs cannot be made.
Cylinder Heads
NOTE: Do not plane or grind more than 0.254mm
(0.010 inch) from original cylinder head gasket
surface.
Replace the cylinder head (6049) if it is cracked.
Remove all burrs or scratches with an oil stone.
Cleaning ROTUNDA TAPEASERT INSTALLATION KIT 107-00901
A6651-O
With the valves installed to protect the valve seats,
remove deposits from the combustion chambers and Thoroughly clean spark plug counter bore, seat
valve heads with a scraper and a wire brush. Be and threads of all dirt or other foreign material.
careful not to damage the cylinder head gasket 2. Start tap into spark plug hole being careful to
surface. After the valves are removed, clean the valve keep it properly aligned.
guide bores. Use cleaning solvent to remove dirt,
As tap begins cutting new threads, apply
grease and other deposits from the valves with a fine
aluminum cutting oil to tap.
wire brush or buffing wheel.
Continue cutting threads and applying oil until
Inspection stop ring bottoms against spark plug seat.
Inspect the cylinder heads for cracks or excessively 3. Remove tap. Remove all metal chips using
burned areas in the exhaust outlet ports. compressed air.
Check the cylinder head for cracks and inspect the 4. Coat threads of mandrel with cutting oil. Thread
gasket surface for burrs and nicks. Small taperset onto mandrel until one thread of mandrel
imperfections of this type can be dressed down using extends beyond taperset.
an oil stone. Replace the cylinder head if it is cracked.
The following inspection procedures are for a cylinder
head that is to be completely overhauled. For TAPERSET
individual repair operations, use only the pertinent
inspection procedure.
Spark Plug Thread Service
NOTE: The use of power or air driven tools is not
approved for the installation of tapersets.
Damaged spark plug threads in the cylinder head can A2345&-A
be serviced using Rotunda Taperset Installation Kit
107-00901 or equivalent. 5. NOTE: A properly installed taperset will be flush
The procedure involves cutting new threads in the to one millimeter below spark plug gasket seat.
spark plug hole. After rethreading operation, a tapered Thread taperset into tapped spark plug hole using
sleeve will be installed in the cylinder head. The sleeve a torque wrench. Continue tightening mandrel until
is threaded on the inside and outside. The outside torque wrench indicates 61 N·m (45 Ib-ft).
threads into the cylinder head while the inside
provides new threads for the spark plug.
The service is permanent and will have no effect on
cylinder head or spark plug life.

ALL RIGHTS RESERVED
6. To loosen mandrel for removal, hold mandrel

stationary and turn mandrel body approximately VALVE SEAT
one-half turn. Remove mandrel. RUNOUT GAUGE
081 P-6002-E
Cylinder Head Flatness Valve Stem-to-Valve Guide Clearance

NOTE: Do not plane or grind off more than 0.254mm
(0.010 inch). SPECIAL SERVICE TOOL(S) REQUIRED
When a cylinder head is removed because of gasket Description Tool Number
leaks, check the flatness of the cylinder head gasket
surface for conformance to specification. For
specifications refer to Section 03-01 A, 03-01 B, or Valve Stem Clearance Tool TOOL-6505-E
03-Q1C, depending on which engine you are servicing.
1. Check the valve stem-to-valve guide clearance of
If necessary to refinish the cylinder head gasket
each valve in its respective valve guide (6510)
surface.
with Valve Stem Clearance TOOL-6505-E or
equivalent. Use a flat-end indicator point.
2. Install the tool on the valve stem until it is fully
seated, and tighten the knurled setscrew firmly.
Permit the valve to drop away from its seat until
the tool contacts the upper surface of the valve
guide.
DIAL
INDICATOR
WITH BRACKETRY
TOOL-4201-C
~
A15267-A
Valve Seat Runout

Check the valve seat runout with Valve Seat Runout
Gauge 081 P-6002-E or equivalent as illustrated
below. Follow the instructions of the gauge
manufacturer. If the runout exceeds the wear limit,
reface the valve and valve seat. For specifications,
refer to the appropriate engine section.
A10707-D

ALL RIGHTS RESERVED
3. Position the dial indicator with its flat tip against NOTE: If oversize valve stems and oversize stem
the center portion of the tool's spherical section seals are not available, bore out original valve guide
at approximately 90 degrees to the valve stem and install service bushing. Ream inside diameter for
axis. specified clearance for standard size valve. Reface
4. Move the tool back and forth in line with the valve seat, as required. Install standard size valve
indicator stem. stem oil seal.
5. Take a reading on the dial indicator without When replacing a standard size valve with an oversize
removing the tool from the valve guide upper valve, always use the reamer in sequence (smallest
surface. oversize first, and then next smallest, etc.) so as not to
overload the reamers. Always reface the valve seat
6. Divide the reading by two, the division factor for after the valve guide has been reamed, and use a
the tool. suitable scraper to break the sharp corner (inside
7. If valve stem-to-valve guide clearance exceeds diameter) at the top of the valve guide.
the wear limit, ream the valve guide for the next NOTE: The interference angle of the valve and seat
oversize valve stem as described in this section. should not be lapped out. Remove all grooves or score
Valves, Select Fitting marks from the end of the valve stem, and chamfer it
as necessary. Do not remove more than 0.254mm
If the valve stem-to-valve guide clearance exceeds the (0.010 inch) from the end of the valve stem.
service clearance, ream the valve guide for the next
oversize valve stem. Valves with oversize stem If the valve face runout is excessive and / or to remove
diameters of 0.38mm and 0.76mm (0.015 inch and pits and grooves, reface the valves to a true 45
0.030 inch) are available for service in diameters of degree angle. Remove only enough stock to correct
0.41 mm and 0.81 mm (0.016 inch and 0.032 inch) the runout or to clean up the pits and grooves. If the
oversize. Always reface the valve seat after the edge of the valve head is less then 0.794mm (1 /32
valve guide has been reamed. Refer to Valve inch) thick after grinding, replace the valve as the
Guides, Reaming. valve will run too hot in the engine.
In the case of valve stem-to-valve guide clearance the If the valve and / or valve seat has been refaced, it will
service clearance is intended as an aid to diagnos{ng be necessary to check the clearance between the
engine noise only, and does not constitute a failure or rocker arm pad and the valve stem with the valve train
indicate need for service. However, when overhauling assembly installed in the engine.
or reconditioning a cylinder head, the service Valve Seats, Refacing
clearance should be regarded as a practical working
value, and used as a determinant for installing the next Measure the valve seat width. Reface the valve
oversize valve to make sure service life is extended. seat(s) if the width is not within specifications. Refer to
the appropriate engine section.
Valve Guides, Reaming Refer to Engine Service in the Rotunda Tool catalog for
If it becomes necessary to ream a valve guide to install a description of the various types of valve seat
a valve with an oversize stem, a hand reaming kit is grinders and cutters available.
available which contains the following reamer and pilot Refacing the valve seat should be closely coordinated
combinations: a 0.38mm (0.0 15-inch) OS reamer with with the refacing of the valve face so that the finished
a 0.076mm (0.003-inch) OS pilot, and a 0.76mm seat and valve face will be concentric and the
(0.030-inch) reamer with a 0.38mm (0.0 15-inch) OS specified interference angle will be maintained. This is
pilot. important so that the valve and seat will have a
compression-tight fit. Make sure refacer grinding
wheels are properly dressed.

ALL RIGHTS RESERVED
Grind the valve seats of all engines to a true 45-degree If the valve seat width exceeds the maximum limit,
angle. Remove only enough stock to clean up pits and remove enough stock from the top edge and / or
grooves or to correct the valve seat runout. After the bottom edge of the seat to reduce the width to
seat has been refaced, use a seat width scale or a specification.
machinist scale to measure the seat width. Narrow the On the intake and exhaust seats, use a eO-degree
seat, if necessary, to bring it within specification. For angle grinding wheel to remove stock from the bottom
specifications, refer to Section 03-01A, 03-01B, or of the seat (raise the seats). A 30-degree angle wheel
03-01C, depending on which engine you are servicing. is used to remove stock from the top of the seats
(lower the seats).
The finished valve seat should contact the
® approximate center of the valve face. It is good
practice to determine where the valve seat contacts
the face.
To do this, coat the seat with Prussian Blue and set the
valve in place. Rotate the valve with light pressure. If
the blue is transferred to the center of the valve face,
the contact is satisfactory. If the blue is transferred to
the top edge of the valve face, lower the valve seat. If
the blue is transferred to the bottom edge of the valve
face, raise the valve seat.
Valves
The critical inspection points and tolerances of the
valve are illustrated below. Refer to Specifications in
VlEWZ Section 03-01 A, 03-01 B, or 03-01 C for service limits.
A23881·A
Inspect the valve stem for bends, and the end of the
stem for grooves or scoring.
Part
Item Number Description Inspect the valve face and the edge of the valve head
for pits, grooves or scores. Inspect the stem for a
1 6507 Intake Valve or bend condition and the end of the stem for grooves or
6505 Exhaust Valve scores. Check the valve head for signs of burning or
A - Valve Seat Angle erosion, warpage and cracking. Minor pits, grooves,
B - Seat Width and Proper etc., may be removed. Discard severely damaged
Location On Valve valves.
C - Bottom Narrowing Angle 75 Inspect the valve spring assembly, valve spring
Degrees retainers, locks and sleeves and discard any visually
D - Top Narrowing Angle 30 damaged parts.
Degrees
E - Valve Face Angle
F - Valve Margin
DIAMETER AND
~-- BENT STEM
VALVE
FACE
ANGLE
A14139-D
A6802-8

ALL RIGHTS RESERVED
Valves, Refacing Valve Spring Squareness

NOTE: Discard any excessively worn or damaged Check each valve spring for squareness using a steel
valve train parts. square and a flat surface. Stand the valve spring and
Minor pits or grooves may be removed. Discard valves square on end of the flat surface. Slide the valve spring
that are severely damaged if the face runout cannot be up to the square. Revolve the valve spring slowly and
corrected by refinishing or if stem clearance exceeds observe the space between the top coil of the valve
specification. Refer to the appropriate engine section spring and the square. Refer to the illustration below.
for specifications.
Refer to Engine Service in the Rotunda Tool catalog for
a description of the various types of valve resurfacing
equipment.
The valve refacing operation should be closely
coordinated with the valve seat refacing operations so
that the finished angles of the valve face and valve
seat will be to specifications and provide a ~ CLOSED COIL END DOWNWARD
compression-tight fit.
Make sure refacer grinding wheels are properly
dressed.
Valve Spring Tension

Valve / Clutch Spring Tester TOOL-6513-00
Inspect the valve spring (6513), valve spring retainers,

and keys for wear or damage. Discard any damaged Refer to Specifications in Section 03-01 A, 03-01 B, or
parts. 03-01 C for out-of-square limits. Follow the same
Check the valve springs for proper pressure at the procedure to new valve springs before installation.
specified spring lengths using Valve / Clutch Spring Make sure the proper valve spring (color-coded) is
Tester TOOL-6513-DD or equivalent. Tighten until installed.
click is heard; read torque wrench and multiply reading
by two. Weak valve springs cause poor engine CAUTION: Make sure the valve springs are
performance. Replace any valve spring not within reassembled to their own original dampers by
specification. For specifications, refer to Section pushing damper on the valve spring. Do not open
03-01 A, 03-01 B or 03-01 C. Manually rotating the damper with any kind of tool in order to
valve spring assemblies while installed in the engine reassemble.
will not determine condition of valve springs.
CAUTION: Make sure the valve springs are
reassembled to their own original dampers by
pushing damper on the spring. Do not open Rocker Arm
damper with any kind of tool in order to Cleaning
reassemble.
Clean all parts thoroughly. Make sure all oil passages
are open.
Make sure oil passage in the push rod end of the
rocker arm (6564) is open.
SET KNOB TO
~nftt'ft"'--COMPRESSED
,--_--a::I LENGTH OF SPRING
A2133D-A

ALL RIGHTS RESERVED
Inspection If the push rod is bent beyond specifications, it should

Inspect the rocker arm seat (6A528) and the rocker be replaced.
arm bore for nicks, scratches, scores or scuffs.
Replace any damaged parts.
ROCKER
ARM BOLT
FULCRUM
DIAL
INDICATOR
WITH BRACKETRY
TOOL-4201-C
ROCKER
ARM HOLDING PUSH ROD
FIXTURE
A10196·C
Intake Manifold
Asasl-E Cleaning
Inspect the pad at the valve end of the rocker arm for Remove all gasket material from the machined
indications of scuffing or abnormal wear. If the pad is surfaces of the upper and lower intake manifolds.
grooved, replace the rocker arm. Do not attempt to Clean the m~nifolds in a suitable solvent and dry it with
true this surface by grinding. On . compressed air.
pedestal-mounted rocker arms, check the rocker Inspection
arm pad, side rails and fulcrum seat for excessive
wear, cracks, nicks or burrs. Check the rocker NOTE: Remove all filings and foreign matter that may
arm bolt for stripped or broken threads. have entered the manifold as a result of service.
Inspect the manifold for cracks, damaged gasket
surfaces, or other problems that would make it unfit for
further service. Replace all studs that are stripped or
Push Rods otherwise damaged. Clean the EGR exhaust
passages.
SPECIAL SERVICE TOOL(S) REQUIRED Check the baffle plate(s) on the underside of the
manifold if so equipped. The baffle(s) should be
Description Tool Number securely fastened.
Cleaning
Clean the push rods (6565) in a suitable solvent. Blow Exhaust Manifold
o~t the oil passage in the push rods with compressed
Cleaning
air.
Remove all gasket or foreign material from all inlet and
Inspection outlet sealing surfaces of the manifolds.
NOTE: Do not attempt to straighten push rods. Inspection
Check the ends of the push rods for nicks, grooves, Inspect the cylinder head joining flanges of the exhaust
roughness or excessive wear. Replace damaged push manifold for evidence of exhaust gas leaks.
rods.
Inspect the manifold for cracks, damaged gasket
The push rods can be visually checked for surfaces, or other damage that would make them unfit
straightness while they are installed in the engine for further service. Warped or cracked exhaust
(6007) by rotating them with the valve closed. They manifolds must be replaced.
also can be checked with a dial indicator.

/
ALL RIGHTS RESERVED
Flywheel Inspection With the flywheel installed on the crankshaft (6303),

check the gear face runout.
Transmission, Automatic
Inspection
Transmission, Manual
Inspect the flywheel (6375) for cracks or other Inspection
damage that would make it unfit for further service. Inspect the flywheel ring gear (6384) for worn,
Inspect the flywheel ring gear for worn, chipped or chipped or cracked teeth. If the teeth are damaged,
cracked teeth. If the teeth are damaged, replace the replace the flywheel ring gear.
ring gear and flywheel assembly.
Flywheel Clutch Surface Machining

Inspect the flywheel (6375) for cracks, heat check, or
other damage that would make it unfit for further use.
Acceptable flywheels may be repaired by polishing
with fine grade (400 grit) sandpaper. Flywheels may
be resurfaced to remove scratches or grooves. After
resurfacing, the flywheel thicknesses must not be less
than the dimensions noted in the chart in
Specifications portion of this section.
• Mount flywheel rigidly on crankshaft mounting
flange.
• After machining:
- Surface runout must not exceed 0.13mm (0.005 A15182-B
inch) TIR; surface finish must be in the range of
4.0/ 1.3 micrometer (160/52 microinch).
Part
Major diameter of dowel pin (press-fit diameter) Item Number Description
must not extend above the new surface.
1 - Dowel Pin (Part of 6375)
- The clutch pressure plate retaining bolts must 2 6375 Flywheel
screw into the flywheel under hand torque to
within 1.50mm (0.06 inch) of new surface.
3 - Ring Gear (Part of 6375)
4 6303 Crankshaft
- Flywheels with dimensions less than the A - Dimension A
charted dimensions must not be used; install B - Dimension B
new service flywheel. C - Dowel Pin Height
Charts D - Pressure Plate Bolt Height
Dimension "A" is the minimum acceptable dimension
from the crankshaft mounting surface to the new
resurfaced clutch face surface. Dimension uB" is a
referenced minimum acceptable dimension for the
overall width of the outer flange.
SPECIFICATIONS
NOTE: For specific engine specifications, refer to

Section 03-01 A, 03-01 B, or 03-01 C, depending on
which engine you are servicing.
GENERAL ENGINE SPECIFICATIONS
Item Dimension
Normal Engine Vacuum at Idle -51 to -74 kPa (15-22 in-Hg)
Maximum Allowable Timing Chain Deflection (5.0l, 5.al and 7.5l) 3. 175mm (0. 12 In.)
Timing Gear Backlash (4.9l) O. 1-0.25mm (0.004-0.010 In.)
Cylinder Block Cylinder Head Deck Flatness - Maximum Variation 0.076mm (0.003 In.) Over 152mm (6 In.)
O. 152mm (0.006 In.) Overall
Cylinder Block Bearing Bore Alignment - Maximum Variation 0.076mm (0.003 In.)
(Continued)

ALL RIGHTS RESERVED
03-00-39 Engine Service, Gasoline 03-0o-3S;
GENERAL ENGINE SPECIFICATIONS (Cont'd)

Item Dimension
Cylinder Block Flywheel Housing Flange Flatness - Maximum Variation 0.076mm (0.003 In.)
Maximum Allowable Cylinder Bore Taper o. 127mm (0.005 In.)
Maximum Allowable Cylinder Bore Out-of-Round O. 127mm (0.005 In.)
Measuring Point for Piston Diameter - Below Oil Ring Groove 16.5mm (0.650 In.)
Required Oil Clearance - Journal to Main Bearing
4.9L 0.023-0.069mm (0.0009-0.0027 In.)
5.0L 0.0 18-0.060mm (0.0007-0.0024 In.)
5.8L 0.046-0.063mm (0.0008-0.0025 In.)
7.5L 0.046-0.063mm (0.0008-0.0024 In.)
Maximum Allowable Crankshaft Runout 0.076mm (0.003 In.)
Maximum Oil Pump Cover Flatness Variation 0.038mm (0.0015 In.)
Oil Pump Rotor Clearance O. 10mm (0.004 In.)
Minimum Engine Valve Margin 0.794mm (1 /32 In.)
Maximum Allowable Camshaft Runout 0.03mm (0.0012 In.)
Flywheel Dimensions
Flywheel Dimension "A" Dimension "8"

Part Number mm (Inch) mm(lnch)
E3TZ-6375-A 25.95 (1.02) 28.45 (1.12)
E69Z-6375-B 28.18 (1.10) 28.85 (1.14)
SPECIAL SERVIC~ TOOLS REQUIRED SPECIAL SERVICE TOOLS DESIRED

To~1Number/ Tool Number Description
D81L-6002-D Piston Ring Groove Cleaner
T50T-100-A
D81P-6002-E Valve Seat Runout Gauge
~
Impact Slide Hammer
D81L-6002-B Plastigage~
T50T·1GO-A
TOOL-4201-C Dial Indicator with Bracketry
T59L-100-B TOOL-6500-E Hydraulic Tappet Leak-Down Tester
Impact Slide Hammer
~ T51L-100-B
TOOL-6505-E
TOOL-6513-00
Valve Stem Clearance Tool
Valve / Clutcl' Spring Tester
T73L-6011-A TOOL-6~65-AB Cup Shaped Adap~er

Engine Cylinder Hone Set
ROTUNDA EQUIPMENT
~~
Mode' Description
112-R0030 Oil Leak Detector Kit
T73L~11-A 059-ROO09 Compression Tester
T73L-6600-A 014-00705 Pressurization Kit
Engi'1e Oil Pressure Gauge 059-00008 Vacuum / Pressur~ Tester
~O 107-R0901 Taperset installation Kit
~
054-00038 Boring Bar
T73L-IIOO-A
1995 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain, privetrain July 1994

ALL RIGHTS RESERVED
03-01A-1 Engine, 4.9L Six-Cylinder 03-01A-1
SECTION 03-01A Engine, 4.9L Six-Cylinder

VEHICLE APPLICATION 03-o1A-1 IN·VEHICLE SERVICE (Cont'd.)
DESCRIPTION AND OPERATION Wat.r Pump •••••..•••••••....••••.....•..•...•.....•.......•.....•03-o1A·19
Camshaft .••.•......••••.•..••••.••••••••.•••••••.•••••••••.•••.•....03-01 A-3 REMOVAL AND INSTALLATION
Crankshaft ••..••••••....•••••..•••••••.•••••.•.••••...•••••.••••••••03-o1A-3 Camshaft .•.•.•••....••••••••.•••••..••.•••..•••.....•.••...••.•...03-o1A·51
Drlv. B.lt Syst.m •••..........•........•.••.•.••••......••.......03-o1A-6 Camshaft B.arlngs ••••.....•••....•.••..•.••.....••.•.••.••...03-01 A-52
Emission Calibration Lab.I •..•••....••••••••.•........•.••..03-o1A-2 Camshaft G.ar •.................•......•......•••.•..••••..•••••03-01A·49
Engln••...•.....•.•••...•.•••••.....••....••••••...•••.......•..•.•••••03-o1A-1 Camshaft R.ar B.arlng Bor. Plug •••...••••....•••.•..•03-o1A·68
Engln. Cod. Information •....•.••..•••••..••••••••...••••••••03-0 1A-2 Conn.ctlng Rod B.arlngs ••..•..•••....••..............•...03-01 A-65
Engln. Cooling Syst.m..•••.••.••...••••..•.••••••..•..•••••..03-o1A·5 Crankshaft •••••.••••••..••••....•••.....•••.......•..........••...03-01 A-59
Engln.ld.ntlflcatlon ••••.••••••...•••••..••••••...•.•.....••.•.03-o1A·2 Crankshaft G.ar .•••.•..•......•..•••..••••....••••••..••••••.••03-o1A-50
Engln. Lubrication Syst.m •••••••••••••.••••.•.•••••••..••••03-o1A-3 Crankshaft Main B.arlngs....••••.•.••••....••••...•••••...03-o1A-62
Exhaust Emission Control Syst.m•••••••••••••.••.•••••..03-o1A·3 Crankshaft Pull.y and/or Crankshaft Front
Induction Syst.m .....•••.••••••••..••••••.••••••...•.•••••.••••.03-o1A·3 S.al ..••••••.•..••...•••••................•...••....•.•........•..•03-Q1A-46
011 Pump ••.•........•••••.•....•••.•••••••.•••.••.....••••...••••..•••03-o1A-4 Crankshaft R.ar 011 S.al ...••••....••••...•••••....•••..••••03-01 A-67
Posltlv. Crankcas. V.ntllatlon Syst.m ••••••••...•••••03-01 A·3 Cyllnd.r H.ad(s) •••••••..••••••...•••..•.••.....•.•.............03-0 1A-45
Valv. Train •••...•.•••••••.••••••..••••••.••••••..•••••••.••..••••...03-o1A-3 Engln. Ass.mbly ...•.•.•••..•.......••••.••••••....•••.•••.••••03-01 A-37
IN-VEHICLE SERVICE Engln. Front Cov.r •....•••...•••••..•.•••.....•••............03-01 A-47
Camshaft •••••.••••••••••••••..•••.•••.••••••••••••••••.••••••••.••03-o1A·23 Exhaust Manifolds .•....•............••.....•.....••.....•••...03-01 A-54
Camshaft R.ar B.arlng Cov.r •••••••••••••••••••..•••••••03-o1A·36 Flywh••I •••.••••...••••••...••••••••••...••••••.•••••••••••••••••••03-o1A·66
Conn.ctlng Rod B.arlngs •••..•...••••..••••.•••••••••...••03-o1A·33 Intak. Manifold ••.•....••••....•.....•••.........•..•.•.....•...03-o1A-43
Crankshaft Front S.al..••....•••....•••••••••••••••••••••••..03-o1A-18 Low.r ••••.•••.•.••••..•..••.......•.....•........•....••....•.••.03-01 A·45
Crankshaft G.ar ...•.••.....•••••••••••••..•.••.••.•••••••••••••03-o1A-22 Upp.r•..••••..•••••••.••••••..••••••••••••...•••....••••.•••..•••.03-o1A-43
Crankshaft Main B.arlngs•.•.••.••••••••••.•••••••.••••••..03-o1A-30 Malnshaft B.arlng Roller..••••...••••..••.••............•.••03-01 A·66
Crankshaft R.ar 011 S.al ••••••.•••••••••••••••••.•..•......•03-o1A-35 011 Fllt.r ..••••.••••••.•..••...•••••...••••.••••••....•••••..•••••...03-o1A-68
Cyllnd.r H.ad.•....•..•••.....•.•••••••.••••..•....•..••.•••.•...03-o1A·16 011 L.vellndlcator Tub•...••••....•••••..•.••....••••...•..•03-01 A·68
Engln. Compon.nts •.•....•..•....•..•.••••••..•..••••....•....03-01 A·6 011 Pan.............•••.•..•...•.•••.....•••••.•••••••.••••••..••••..•03-o1A-57
Engln. Front Cov.r .........•.•.•.••••••••••••••••••.•••••.•••03-o1A·20 011 Pump •••.•••••..•.••••.••••••..••••..•••••••..•••••..•••••..•••••03-o1A·58
Exhaust Manifolds ••...•••••.•.••••••••.•.••••••••••••••...••••03-01 A·25 Pistons and Conn.ctlng Rods ••..•••..........•...•....••03-o1A-64
Flywh••I ....•..•.•.•••••••..••••••••••...•..•.••••••••..•••••..••••03-o1A·34 Rock.r Arm •••.••••.•.....•••..•..•..•...•.•.••••.•••••...•••••••.03-0 1A-40
Intak. Manifold .................•.•.••.•••••••....••......•.....03-o1A·13 S.n80rs••.....••••..•.•••••.••.....••••....••••..•..••......•••.....03-0 1A·69
Low.r ..••••••..........•.••••••.••••••••••.••••••••••••••...•••••03-01 A·16 011 Pr.ssur. Switch •••.•••....•.•.........•.•....•...••...•03-o1A-69
Upp.r•••••••.••••••••••....••.•...••••..••••••••..••.•••.•.•••..•.03-01 A·13 nmlng G.ars ••••..••••.••••.•...•••••. ~..•••....•••••...•••••.•.••03-o1A-49
Malnshaft B.arlng RolI.r.•.••••••••.••••••.....•••.....••...03-o1A·34 Valv. Cov.r and Gask.t••...•..••......•........•....•......03-o1A-39
011 Fllt.r ...••.••••••....•••.•••....••••..•••.•••••••••••••••••••••••03-o1A·36 Valv. Spring, R.taln.r and Valv. St.m
011 L.v.llndlcator Tub•.•..•••••••.•••••••••.••••••..•••••••03-o1A-36 S.al ..•••••••..•.•••••..•••....•••...••••••.•.••••......•...•..•...03-o1A-40
011 Pan and / or 011 Pump Scr••n Cov.r and Valv. Tapp.t, Hydraulic 03-o1A-42
Tub•.•.••••.•..••••••••.•..•••••••••••.••.••••••••••••••..••••••••03-o1A·28 Wat.r Pump ••...••••..••••••.•••••..•••••••.••••••••.••••••.••••••03-o1A-47
011 Pump ....••.••••.•....•.•.••••••••..••.•••••••..•..•.....•••..•••03-o1A·30 DISASSEMBLY AND ASSEMBLY
Pistons and Conn.ctlng Rods .••••••••••••••.•..•••••...•03-o1A·32 Cyllnd.r Block AS8.mbly ....••......•.......•.••....••.•...03-o1A-75
Rock.r Arm ••••.•.•..•••••••••...•••••••••••••••••••••••••••••••••03-o1A·11 Cyllnd.r Block, Bar••••.....••....•••••...•••..•..............03-o1A·75
S.nsors....•.•.•••.••••..•.••••••••.••••••••••••••••••.•••••••••...•03-01 A-37 Subass.mbll••••.•••••.•••••••.••••••.•••••••.••••••...•..•....•03-0 1A-69
011 Pr.ssur. S.nd.r Switch •••••••••..•..••.•.•••••••••03-o1A·37 Cyllnd.r H.ad .••.•••••••••....•••••••.••••••..••••••..••••••.03-01 A-69
nmlng G.ars •••••••..•••••••••••••••••.••••••••••••••••••••••••••03-01 A·21 PI8ton and Conn.ctlng Rod ••••...•.•.....•••....•••••.03-o1A-72
Camshaft G.ar .•.••.••••••••.•••••••.•..••••••••••..•••••.•.•03-o1A·21 Valv. Tapp.t, Hydraulic ••....••.......••.....••.......•...•.03-o1A-74
Valv. Cov.r and Gask.t 03-Q1A·10 ADJUSTMENTS
Valv. Spring, R.taln.r and Valv. St.m Valv. CI.aranc•......••..............•....•.•••.•.•.•••.••.•.••03-o1A-75
Seal •.••••..•.•........•••••••••••••......•••••••••••••••••••.•••••03-o1A·11 SPECIFICATIONS •••••••••••••.•••••••••••••••••••••••••••••.••••••03-0 1A-76
Valve Tapp.t, Hydraulic ••...•...•••••...•..••.••.••.••••••.•03-o1A·12 SPECIAL SERVICE TOOLS/EQUIPMENT .•.•............03-01A-81
VEHICLE APPLICATION
F-1SQ-2S0-3S0 (4x2), F-150-250 (4x4)
Engine • Seven main generic bearings supporting the engine.

The 4.9L (300 cubic inch) engine (6007) is of the • Crankshaft (6303) made of special high grade cast
in-line six cylinder overhead valve type with the iron.
following features. • Aluminum pistons with integral steel struts to control
expansion.

ALL RIGHTS RESERVED
• Stamped steel rocker arms (6564) which pivot on

MFD. BY FORD MOTOR CO. IN CANADA
powdered metal cylindrical fulcrums.
DATE: 09-87 GVWR: 5347 LB-2425 KG
• Hydraulic valve tappets (6500). FRONT GAWR: 2714 L8 REAR GAWR: 2683 LB
1231 KG 1216 KG
• A complete circle (not split) crankshaft rear oil seal
(6701).
• Liquid cooling through cooling jackets cast integral VEHICLE SAFETY AND BUMPER STANDARDS IN EFFECT ON THE
DATE OR MANUFACTURE SHOWN ABOVE.
with the cylinder block (6010) and cylinder head
(6049). Cylinder block jackets are of the full-length
type in that they extend to the bottom of the cylinder
bores. 1=
482450
DSO
Engines with 49-state emissions calibration or AX TA
California calibration and manual transmission or C6 B 8 TSBBS
automatic, have a multipart fuel injection (MFI) system.
Engines with California emissions calibration and
E40D transmission have a sequential fuel injection ENGINE CODE
(SFI) system. (8TH CHARACTER)
A23412·A
Among the visible differences of the SFI engine:
• EGR valve to exhaust manifold tube (9D477) with Code Engines Fuel Metering
hose nipples for EGR transducer hoses. y 4.9L (300 CID) MFI
• EGR transducer (9J433) (delta PFE sensor) and
bracket mounted on upper intake manifold.
• Intake air temperature sensor (IAT
sensor)( 12A697) relocated from lower intake Engine Code Information
manifold to air cleaner outlet tube (9B659). Located in three places is the engine code information
• A heated oxygen sensor (H02S)(9F472) on each label containing an engine build date, an engine plant
exhaust manifold just above the exhaust pipe code, and an engine code. The engine code
flange. information label is found in the following places:
1. Valve cover (6582), Front - On F-Series
vehicles, this label will be the easiest to locate.
2. Cylinder head (6049), Back
Engine Identification
3. Engine front cover (6019)
For quick engine identification, refer to the Safety
Certification Decal.
• The decal is mounted on the LH front door lock face TYPICAL ENGINE CODE LABEL
panel. ENGINE PLANT ENGINE CODE
• An build code and information label (6E072) is also CODE J ENGINE BUILD
~ FK2sGAA+12
attached to the engine (6007).
• The symbol code on the build code and information
label identifies each engine for determining parts
usage; for instance, engine cubic inch displacement
(CID) and model year. 10 16 84
IIII~IIIIII~ III~IIIIIID~III~ II~II~III DIIII

Al308-C
Emission Calibration Label

The emission calibration number label is located on the
left side door or left door post pillar. It identifies the
engine calibration number and revision level.
These numbers are used to determine if parts are
unique to specific engines.

ALL RIGHTS RESERVED
NOTE: The engine codes and the calibration number • Has end play controlled by a camshaft thrust plate
must be used when ordering parts or making inquiries (6269) behind the camshaft timing gear. The
about the engine (6007). camshaft thrust plate bolts to the front of the
cylinder block (6010).
• Is driven by two helical-cut timing gears. The
CALIBRATION crankshaft timing gear is steel; the camshaft gear is
phenolic resin.
ErALONNAGE ~
CALIBRACIDN
2-54E-ROO E8AE-6E061-ABY
Valve Train
A10693·B
The valve train consists of:
• Hydraulic valve tappets (6500)
• Pushrods(6565)
Exhaust Emission Control System • Rockerarms(6564)
The exhaust emission control devices used on these • Rocker arm fulcrums
engines (6007) are covered in the Powertrain • Rocker arm fulcrum guides (6A588)
Control/Emissions Diagnosis Manual. 1 • Fulcrum retaining bolts
Camshaft motion is transmitted through the valve train
to th~ engine valves. The hydraulic valve tappets
automatically adjust valve lash for silent operation.
Induction System The push rods are made of tubes with welded-on,
The air induction system for this system consists of: hardened steel ends drilled for oil passage. Each
rocker arm is individually mounted with a fulcrum bolt.
• A two-piece aluminum intake manifold (9424) with Each rocker arm pivots en its fulcrum. Each rocker
runners tuned to optimize engine torque and power arm fulcrum guide serves two rocker arms.
output.
• A throttle body (9E926) which controls engine
airflow with two throttle plates and an idle air control
valve (lAC valve)(9F715). Positive Crankcase Ventilation System
• Six fuel injectors are mounted in the intake manifold These engines (6007) are equipped with a positive,
so that they spray fuel into the intake valve port. closed-type ventilation system which directs the
For more information on the fuel and induction system, crankcase vapors to the intake manifold (9424) for
refer to Section 03-048. combustion.
Crankshaft Engine LubricatiC'n System

The crankshaft (6303): Oil from the oil pan (6675) is forced through the
pressure-type lubrication system by a rotor-type oil
• Is made from precision cast nodular iron. pump. A spring-loaded relief valve in the oil pump
• Has seven main bearings so each connecting rod is (6600) limits the maximum pressure of the system. Oil
between two main bearings. relieved by the valve is directed back to the intake
side of the oil pump.
• Thrust is taken on the fifth main bearing to control
end play. From the oil filter, the oil flows into the main oil gallery.
The oil gallery supplies oil to all the camshaft bearings
• Has a vibration damper consisting of a cast iron and crankshaft main bearings.
inner and outer ring with rubber compressed
between them to help control torsional vibration. The crankshaft (6303) is drilled from the main
bearings to the connecting rod journals to lubricate the
connecting rod bearings (6211).
Oil from the floor of the valve tappet chamber is fed
Camshaft through a drilled passage to lubricate the distributor
shaft, bushings and the oil pump intermediate shaft
The camshaft (6250), which operates the engine (6A618).
valves:
• Is supported by four bearings pressed into the
cylinder block.


ALL RIGHTS RESERVED
The main oil gallery intersects all of the valve tappet Excess oil in the push rod chamber drains back into
bores supplying pressurized oil to the hydraulic valve the oil pan through openings along the cylinder block.
tappet (6500). A reservoir at each valve tappet bore
boss traps oil so that oil is available for valve tappet
lubrication as soon as the engine starts.
When the hydraulic valve tappets are on the base
circle of the camshaft lobe (valve closed), the oil hole
in the hydraulic valve tappet is indexed with the oil
gallery, and oil flows into the plunger. Oil is also
metered through the metering valve (disc), through the
oil passages in the push rod cup, and it flows up the
hollow push rod (6565). In this position, the drilled hole
in the ball end of the push rod is indexed with a drilled
hole in the rocker arms (6564), and the oil lubricates
the upper valve train bearing areas. Excess oil is
returned to the oil pan through drain holes along the
side of the cylinder head (6049) and cylinder block
(6010).
Oil Pump The oil pan:

The oil pump (6600) is of the rotor type with an inner • Is of the pressed-steel type and is attached to the
rotor which turns inside of an outer rotor ring which is bottom of the engine (6007).
off center. It is driven off the camshaft (6250) by the
distributor drive gear through an oil pump intermediate It serves as a reservoir for engine oil and receives oil
shaft (6A618). The pump is mounted to the bottom of after it has been pumped through engine bearings and
the cylinder block (6010) inside the oil pan (6675) and orifices to be reused by the engine..
contains a pressure relief valve. To deliver sufficient The oil pan allows some oil cooling through the pan
pressure and volume at low rpm, it has to be designed walls.
to provide excess pressure and volume at high rpm.
To prevent damage or excess oil consumption, the
pressure relief valve drains off the excess pressure
and volume at high rpm.
Engine Lubrication, 4.9L Six Cylinder

ALL RIGHTS RESERVED
Engine Lubrication System
LUBRICATION SYSTEM
A21332-B
Part Part
1 - Oil Passageway (Part of 4 - Oil Orifice Gear (Part of
6010) to Oil Pressure 6010) to Camshaft Gear and
Sending Unit Crankshaft Gear
2 6600 Oil Pump 5 6211 Connecting Rod Bearings
3 87838-S Plug, Hex 3/8-18 x 0.42 6 6333 Crankshaft Main Bearings
(Continued) 7 6261 Camshaft Bearings
Engine Cooling System

As the coolant flows through the cylinder block
(6010), it travels through passages to cool the entire
length of each cylinder wall. The coolant is then
directed upward into the cylinder head where it cools
the combustion chambers, valves and valve seats.

ALL RIGHTS RESERVED
03-01A-~ Engine, 4.9L Six-Cylinder 03-01A-6
The coolant from the cylinder head (6049) flows into Drive Belt System
the water outlet connection. If the water thermostat Engine accessories, such as the water pump (8501),
(8575) is open, the coolant flows through the water generator voltage regulator wiring (14305), power
thermostat and into the top of the radiator. If the water steering pump (3A674) (if equipped) and A / C
thermostat is closed, the coolant is returned to the compressor (19703) (if equipped) are driven off the
water pump (8501) for recirculation. crankshaft by a single poly-V belt. Belt tension is
automatically held to the correct amount by a
spring-loaded drive belt tensioner (6B209). For more
information on the accessory drive system, refer to
Section 03-05, Drive Belt System.
IN-VEHICLE SERVICE
Engine Components .
The following exploded views of the engine (6007) are
typical and will serve as a reference for the
procedures. The numbers and part des<?ri~tions.
shown are basic part numbers corresponding with the
Ford Master Parts Catalog.
Refer to the end of this section for all specifications
and torque values.
A2274-C

ALL RIGHTS RESERVED
IN-VEHICLE SERVICE (Continued)
MFI Engine Components, Upper (SFI Similar)

ALL RIGHTS RESERVED
I'N-VEHICLE SERVICE (Continued)
Part Part
1 6853 Crankc,ase Ventilation Hose 37 6521 Gasket
2 390659-S 100 PCV Connector 38 6519 Valve Pushrod Cover
3 9A474 Intake Manifold Vacuum 39 14A163 Wiring Harness Retainer
Outlet Fitting and Cap 40 12A310 Ignition Coil and Bracket
4 9424 Intake Manifold, Upper Assembly
5 90476 EGR Valve Gasket 41 18801 Radio Ignition Interference
6 9E936 Throttle Body Gasket Capacitor
7 9F483 EGR External Pressure Valve 42 6714 Oil Filter
8 9F715 Idle Air Control Valve 43 6890 Oil Filter Mounting Insert
9 90477 EGR Valve to Exhaust 44 6010 Cylinder Block
Manifold Tube 45 6020 Engine Front Cover Gasket
10 9F670 Idle Air Control Gasket 46 6019 Engine Front Cover
11 9J444 Intake Manifold Support 47 6700 Crankshaft Front Seal
12 SE926 Throttle Body 48 6312 Crankshaft Pulley
13 9723 Accelerator Cable Bracket 49 6023 Timing Pointer
14 390056-S Bolt (Studded Head) 50 8501 Water Pump
16 6766 Oil Filler Cap 51 8555 Water Bypass Tube
17 6A768 Crankcase Vent Filter 52 8592 Thermostat Housing
18 6A892 Crankcase Ventilation 53 8575 Water Thermostat
Grommet 54 6051 Head Gasket
19 6A892 Crankcase Ventilation 55 8255 Thermostat Gasket
Grommet 56 12A648 Engine Coolant Temperature
20 6A666 Positive Crankcase Sensor
Ventilation Valve 57 18599 Hot Water Heater Elbow
21 - Clip (Part of 14A163) Connection
22 14A163 Wiring Harness Retainer 58 9F593 Fuel Injector
23 390056-S Bolt (Studded Head) 59 9S441 Fuel Injection Supply
24 9H465 Secondary Air Injection Manifold
Control Solenoid Vacuum 60 90930 Fuel Charging Wiring
Valve 61 12A697 Intake Air Temperature
25 9J459 EGR Vacuum Regulator Sensor
Control 62 9439 Intake Manifold Gasket
26 6582 Valve Cover 63 9B445 Secondary Air Injection
27 6584 Valve Cover Gasket Manifold
28 6049 Cylinder Head 64 9A487 Secondary Air Injection
29 12405 Spark Plug Check Valve
30 12106 Distributor Cap 65 9430 Exhaust Manifold, Front
31 12286 Distributor to Spark Plug 66 17A084 Engine Lifting Eye
Wire 67 9430 Exhaust Manifold, Rear
32 12200 Distributor Rotor 68 9H486 Intake Manifold Upper
33 12127 Distributor Gasket
34 14289 Engine Gauge Feed Wire 69 9424 Intake Manifold, Lower
35 9278 Oil Pressure Sensor 70 390717-S56 Spring Clip
36 12A699 Knock Sensor 71 9471 Intake Manifold Shield
(Continued)
ALL RIGHTS RESERVED
MFI Engine Components, Lower (SFI Similar)
®-~
70
A24052-A
Part Part
1 6514 Valve Spring Retainer 18 34792-S36 Washer (6 Req'd)
2 6518 Valve Spring Retainer Key 19 387299-S2 Bolt (6 Req'd)
3 6514 Valve Spring Retainer 20 7563 Clutch Pressure Plate
4 6513 Valve Spring 21 391286 Bolt (6 Req'd)
5 6571 Valve Stem Seal 22 6375 Flywheel (Manual
6 6A528 Rocker Arm Seat Transmission)
7 6564 Rocker Arm 23 7600 Pilot Bearing
8 6A588 Rocker Arm Fulcrum Guide 24 7007 Engine Rear Plate
9 6049 Cylinder Head 25 6A674 Oil Pan Flange
Reinforcement (Left)
10 6565 Push Rod
26 6675 Oil Pan
11 6507 Intake Valve
27 6734 Oil Pan Drain Plug Gasket
12 6505 Exhaust Valve
28 6730 Oil Pan Drain Plug
13 6051 Head Gasket
29 390674-82 Bolt (3 Places)
14 7007 Engine Rear Plate
30 6A674 Oil Pan Flange
15 6375 Flywheel Auto Trans Reinforcement (Right)
(C61 E40D 14R70W)
31 6710 Oil Pan Gasket
16 6379 Bolt (6 Req'd)
17 7550 Clutch Disc (Continued)
(Continued)
ALL RIGHTS RESERVED
Part Part
32 6622 Oil Pump Screen Cover and 51 - Front Cap (Part of 6010)
Tube 52 6333 Crankshaft Main Bearing
33 6600 Oil Pump 53 6312 Crankshaft Pulley
34 6A618 Oil Pump Intermediate Shaft 54 6256 Camshaft Gear
35 376809-5 Cylinder Block Plug 55 6269 Camshaft Thrust Plate
36 87838-S101 SetScrew 56 6019 Engine Front Cover
37 6500 Valve Tappets (12 Req'd) 57 6306 Crankshaft Gear
38 6A008 Cylinder Head to Block 58 379153-S Key
Dowel (2 Req'd)
59 6261 Camshaft Bearings
39 6397 Flywheel Housing to Block Camshaft Sprocket Spacer
60 6265
Dowel (2 Req'd)
61 74148-S Key
40 6333 Crankshaft Main Bearing
62 6250 Camshaft
41 6337 Crankshaft Thrust Main
Bearing 63 6262 Camshaft Center Bearing
42 6701 Crankshaft Rear Oil Seal 64 6010 Cylinder Block
43 6303 Crankshaft 65 - Connecting Rod Cap
(Part of 6200)
44 6337 Crankshaft Thrust Main
Bearing 66 6211 Connecting RocfBearing
45 - Rear Cap (Part of 6010) 67 6200 Connecting Rod
46 - Rear Intermediate Cap 68 6148 Partial Piston Ring Set
(Part of 6010) 69 6102 Piston, Pin and Ring
47 - Rear Center Cap 70 6100 Piston and Rod Assembly
(Part of 6010) A - Tighten to 20-34 N·m
48 - Center Cap (Part of 6010) (15-25 Lb-Ft)
49 - Front Center Cap B - Tighten to 16-24 N·m
(Part of 6010) (12-18 Lb-Ft)
50 - Front Intermediate Cap
(Part of 6010)
(Continued)
Valve Cover and Gasket 5. Remove th~ positive crankcase ventilation valve
(PCV valveX6A666) from 'the valve cover.
SPECIAL SERVICE TOOL(S) REQUIRED Remove the crankcase vent filter. Remove the
cover bolts and remove the valve cover. Inspect
Description Tool Number the valve cover bolts for worn or damaged seals
Fuel Line Removal Tool T93T-9550-AH under the bolt heads and replace as neces~ary.
Removal Installation
1. ,Clean the valve cover (6582) and the gasket
1. CAUTION: When disconnecting accelerator surface of cylinder head (6049). Place the new
cable (9A758) from ball stud, use a valve cover gasket (6584) on cylinder head
screwdriver or similar tool close to the ball making sure that the1abs of the gasket face
stud to pry off. Removing by hand may down toward the head. No sealer or adhesive is
damage the cable. necessary.
Disconnect the inlet air hose at the crankcase
2. Install the valve cover on the cylinder head. Make
vent filter (6A768). Remove the air cleaner outlet
sure the valve cover gasket seats evenly all
tube (98659).
around the cylinder head. Partially tighten the
2. Disconnect the accelerator cable at the throttle cover bolts in an opposing pattern, starting at the
body (9E926). Position the accelerator cable out middle bolts. Then tighten the bolts to 8-14 N·m
of the way. (70-124 Ib-in) in the same sequence.
3. Disconnect the fuel lines with Fuel Line Removal 3. Install the positive crankcase ventilation valve in
Tool T93T-955Q-AH. Do not bend the fuel lines. the valve cover. Install the accelerator cable to
4. Remove the upper intake manifold (9424) and the throttle body.
throttle body. 4: Install the upper intake manifold, throttle body
and EGR valve to exhaust manifold tube (90477).

ALL RIGHTS RESERVED
oa-01A-11 Engine, 4.9L Six-Cylinder 03-01A-11
5. Install the fuel lines at the fuel injection supply

manifold (90280) with Fuel Line Removal Tool
T93T-9550-AH.
6. Connect the inlet air hose to the crankcase vent
filter.
7. Install air cleaner outlet tube.
Rocker Arm
Rocker arm (6564) removal and installation steps are
the same whether the engine (6007) is installed or
removed. Refer to the Rocker Arm procedure in
Removal and Installation.
Valve Spring, Retainer and Valve Stem Seal

Valve Spring Compre~sor T70P-6049-A
Valve Stem Seal Replacer T87L-6511-BH
Broken valve springs (6513) or worn or damaged 4. Remove the push rod (6565). Place a block of
valve stem seals (6571) and valve spring retainer wood on top edge of valve spring retainer and ~ap
(6514) may be replaced without removing the cylinder moderately with a hammer to unlock valve spnng
head providing damage to the valves or valve seats retainer keys (6518). Install the bolt and position
has not occurred. the Valve Spring Compressor T70P-6049-A as
Removal shown in the previous illustration. Compress the
valve spring and remove the valve spring retainer
1. NOTE: In vehicle, removal and installation keys, valve spring retainer and valve spring.
procedures apply to both intake valves (6507) Remove and discard the valve stem seal.
and exhaust valves (6505).
If air pressure fails to hold the intake valve in
Remove the valve cover (6582). (Refer to Valve the closed position during this operation, it
Cover and Rocker Arm procedure in this section.) can be presumed that the intake valve is not
Remove the applicable spark plug (12405). seating or is damaged. If this condition
2. Crank the engine (6007) until the applicable occurs, remove the cylinder head (6049) for
piston is on TOC at the end of the compression further inspection.
stroke.
3. Install a suitable Valve Holdup Air Adapter in the
spark plug hole and connect the air line.
SEAL
AIR LINE
A10099-8
ALL RIGHTS RESERVED
IN-VEHICLE SERVICE (Cont~· J,-d)
5. If air pressure has forced the piston assembly to 3. Disconnect the distributor to spark plug wires at
the bottom of the cylinder, any removal of air the spark plugs (12405) using Spark Plug Wire
pressure will allow the intake valve to fall into the Remover T74P-6666-A. Remove secondary high
cylinder. A rubber band, tape or string wrapped tension wire from the coil. Remove the distributor
around the end of the valve stem will prevent this cap (12106), distributor adapter, and distributor
condition and will still allow enough travel to to spark plug wire (12286) assembly.
check the intake valve for binds. 4. Remove the valve tappet side cover.
6. Inspect the intake valve stem for damage. Rotate 5. Loosen the rocker arm bolts until the rocker arms
the valve and check the valve stem tip for can be disengaged from the push rods (6565).
eccentric movement during rotation. Move the Remove the push rods. Remove the valve
intake valve up and down through normal travel in tappets (6500) with the tool shown. If more than
the valve guide and check the stem for binds. If one push rod and valve tappet are removed,
the intake valv~ has been damaged, it will be place the parts in a rack so they can be installed
necessary to remove the cylinder head and valve in their original locations.
as outlined in this section and replace.
7. If the condition of the intake valve proved
satisfactory, hold the intak~ valve in the closed
position and apply air pre. Jre within the
7
cylinder.
Installation
1. Install new valve spring retainers. Use a 5/ 8-inch
deep well socket and a light hammer or mallet to
seat the valve spring rei:ainer on the valve guide
or use Valve Stem Seal Replacer T87L-6571-BH.
Place the valve spring in position over the intake
valve and install the valve spring retainer.
Compress the valve spring and install the valve
spring retainer keys. Remove the compressor
tool.
o
2. Apply Multi-Purpose Grease DOAZ-19584-AA or
equivalent meeting Ford specification
~-C
ESB-M 1C93-A to both ends of the push rod.
Install the push rod. Apply Multi-Purpose Grease A101OG-1A
DOAZ-19584-AA or equivalent meeting Ford
specifications ESB-M 1C93-A to the top of the Installation
valve stem. 1. NOTE: Refer to Section 03-00 for the cleaning,
3. Turn off the air and remove the air line and inspection and testing procedures.
adapter. Install the spark plug and connect the Clean the external surfaces of the valve tappets,
distributor to spark plug wire. (Refer to Valve valve cover, cylinder head (6049) and cylinder
cover and Rocker Arm procedure in this section. block (6010) gasket surfaces.
'ESB-M1C93-A to the cam lobe contact surface of
Valve Tappet, Hydraulic the valve tappets. Coat the rest of the valve
tappets with engine oil. Install the valve tappets
SPECIAL SERVICE TOOL(S) REQUIRED with the tool shown under Removal.
Description Tool Number 3. Apply Multi-Purpose Grease DOAZ-19584-AA or
Spark Plug Wire Remover T74P-6666-A
ESB-M1C93-A to both ends of the push rods.
Removal Install the push rods in sequence. Engage the
rocker arms with push rods and tighten the
1. Remove the coil and bracket attaching nuts and rocker arm bolts sufficiently to hold the push rods
position the coil and bracket out of the way. in place. Make sure each push rod is properly
2. Remove the valve cover (6582). Refer to Valve seated in the valve tappet socket portion of
Cover and Rocker Arm procedure in this section the valve tappet.
but do not remove the valve rocker arm bolt, 4. Adjust the valve clearance. Refer to Adjustments
rocker arm seat (6A528) or rocker arm (6564). in this section.
ALL RIGHTS RESERVED
5. Coat one side of a new valve pushrod cover

gasket with Perfect Seal Sealing Compound INTAKE MANIFOLD VACUUM PCV
B5A-19554-A or equivalent meeting Ford OUTLET FiniNG AND FITTING
specification ESE-M4G 115-A, and position to the CAPS-9A474
pushrod cover. Install pushrod cover. Alternately,
tighten the cover screws to 2.8-4.0 N·m (25-35
Ib-in). Clean the valve cover. Place the new valve
cover gasket (6584) in the valve cover. Install the
valve cover. Refer to Valve Cover and Rocker
Arm procedure in this section.
6. Position the ignition coil (12029) on the cylinder
block and install the attaching bolt or nuts.
7. Install the distributor adapter, distributor cap and
distributor to spark plug wires. Connect the
distributor to spark plug wires and ignition coil to
distributor high tension wiring (12298).
Intake Manifold
Upper
Removal
1. Disconnect the electrical connectors at:
• EGR external pressure valve (9F483).
V5844-E
• throttle position sensor (TP sensor)(9B989).
3. On SFI engines, tag EGR transducer hoses.
• idle air control valve (lAC valve)(9F715).
Remove two screws, EGR transducer and
• EGR transducer (9J433) (if equipped). bracket, and disconnect hoses.
2. Disconnect the following vacuum connections: 4. Disconnect the PCV hose from the fitting, located
on the underside of the upper intake manifold
• vacuum line at the EGR external pressure (9424).
valve.
5. CAUTION: When disconnecting throttle
• Evaporative Emission (EVAP) system lines to cable from ball stud, use a screwdriver or
the throttle body (9E926) and evaporative similar tool close to the ball stud to pry off.
emission canister purge valve (EVAP canister
Removing by hand may damage the cable.
purge valves)(9C915), if equipped.
Remove the accelerator control splash shield
• vacuum lines to the upper intake manifold (9E766), and disconnect the accelerator cable
vacuum outlet fitting and cap (9A474) vacuum
(9A758) and speed control actuator (9A825).
tree. Labeling the hose locations with tape is
Position the cable away from the engine.
recommended to aid installation.
6. Disconnect the air cleaner outlet tube (9B659)
from the throttle body.
ALL RIGHTS RESERVED
7. Disconnect the EGR valve to exhaust manifold

tube (90477) from the EGR external pressure
valve and the rear exhaust manifold (9430).
Remove the EGR valve to exhaust manifold tube
from the engine (6007).
Part
1 9F483 EGR External Pressure Valve
2 - Connector (Part of 90477)
3 9424 Intake Manifold (Upper)
4 9430 Exhaust Manifold (Rear) Part
5 90477 EGR Valve to Exhaust Item Number Description
Manifold Tube
A - Tighten to 34-47 N·m 1 9424 Intake Manifold (Upper)
(25-35 Lb-Ft) 2 9H486 Intake Manifold Upper
Gasket
8. Remove the screw and washer assembly 3 12A697 Intake Air Temperature.
attaching the intake manifold support (9J444) to Sensor
the upper intake manifold. 4 390715 Stud (7 Req.)
5/16-18 x 2.505
9. Remove the seven studs that retain the upper
intake manifold. 5 9424 Intake Manifold (Lower)
6 390659-8100 PCV Connector
7 9A474 Intake Manifold Vacuum
Outlet Fitting and Cap
(12-18 Lb-Ft)

ALL RIGHTS RESERVED
10. Remove the upper intake manifold and throttle 6. Connect the PCV hose to the fitting, located on
body from the lower intake manifold. the valve cover (6582) under the upper intake
manifold.
7. Connect accelerator cable, transmission
FRONT OF ENGINE kickdown cable, and speed control actuator.
"., Install accelerator control splash shield.
8. Connect the air cleaner outlet tube to the throttle
body.
9. On SFI engines, install EGR transducer and
bracket. Tighten screws to 17-24 N·m (12-18
Ib-ft). Connect EGR transducer hoses.
V5847·F
Part
1 9E936 Gasket
2 45357 Nut 5/16-18
3 9728 Bracket, Accelerator Cable
4 9E926 Throttle Body
5 390757 Screw and Washer
Assembly 7/16-14 x 1.5
Assembly 3/8-16 x .88
7 9J444 Intake Manifold Support
(22-32 Lb-Ft)
B -
Installation
Tighten to 19-27 N·m
(14-20 Lb-Ft)
•
FRONT OF ENGINE
A24046·A
1. Position a new intake manifold upper gasket
(9H486) on the lower intake manifold, using the
lower manifold dowels to position the intake Part
manifold upper gasket. Item Number Description
2. Position the upper intake manifold onto the lower 1 - EGR Hoses (Part of 90477)
intake manifold, using the dowels of the lower 2 9J433 EGR Transducer
intake to locate manifold holes. Install the seven 3 390657-82 Bolt 5/16-18 x 1.12
studs to attach the upper intake manifold to the 4 - EGR Transducer Bracket
lower intake manifold and hand-tighten. 5 9424 Upper Intake Manifold
3. Tighten the seven studs attaching the upper 6 90477 EGR Valve to Exhaust
intake manifold to the lower intake manifold to Manifold Tube
16-24 N·m (12-181b-ft). A - Tighten to 16-24 N·m (12-18
4. Position the upper intake manifold support onto Ib-ft)
the boss of the upper intake manifold, located 10. Connect the following vacuum connections:
under the throttle body. Install the retaining screw
and tighten to 30-43 N·m (22-32 Ib-ft). • vacuum line to the EGR external pressure
5. Install the EGR valve to exhaust manifold tube valve.
between the EGR external pressure valve and the • Evaporate Emission (EVAP)system lines to
rear exhaust manifold. The tube is routed throttle body.
between lower intake runners No.5 and No 6.
Tighten both fittings to 34-47 N·m (25-35Ib-ft). • vacuum lines to the upper intake manifold
vacuum outlet fitting and cap vacuum tree.
ALL RIGHTS RESERVED
11. Connect the following electrical connectors at: 3. Disconnect the fuel lines from the fuel injection
supply manifold (90280) with Fuel Line Removal
• throttle position sensor. Tool T93T-9550-AH.
• idle air control valve. 4. Disconnect transmission oil cooler lines and
• EGR external pressure valve. remove the radiator (8005). Refer to Section
03-03.
• evaporative emission canister purge valve, if
equipped. 5. Remove the cooling fan, drive belt idler bracket
(8A610), water pump pulley (8509) and drive belt
(8620) as outlined in Section 03-05.
IDLE AIR
CONTROL VALVE THROTILE 6. Remove accelerator control splash shield
ELECTRICAL POSITION
SENSOR (9E766) and disconnect the accelerator cable
CONNECTOR
98989 (9A758), transmission kickdowh cabie (C6 only),
and speed control actuator (9A825) at the
throttle body.
7. Disconnect the power brake vacuum line at the
intake manifold vacuum outlet fitting and cap
(9A474).
8. Disconnect the exhaust manifolds (9430) from
the dual converter Y pipe (5F250). Disconnect
the battery ground cable at the engine (6007).
V5842..F 9. Disconnect the engine gauge feed wire (14289)
from the powertrain control module
Lower (PCM)( 12A650).
Removal and Installation 10. Disconnect the engine control sensor wiring
(12A581) and fuel charging wiring (90930) and
NOTE: The lower intake manifold and exhaust related connectors. Position 'the harnesses out of
manifolds must be removed together. To remove the the way.
lower intake manifold, follow the steps outlined for
11. Remove the generator mounting bolts and
removing the exhaust manifolds in this section.
position the generator (GEN)( 10300) out of the
way, leaving the wires attached. Remove the
secondary air injection pump (AIR pump)(9A486)
from generator mounting bracket (10153).
Cylinder Head Remove the generator mounting bracket from
engine.
12. Remove power steering pump (3A674) from the
De8crlptlon Tool Number A I C compressor mounting bracket (2882) and
position it right side up and to one side, leaving
the lines attached. If equipped with A/C
Engine Lifting Bracket T70P-6000
compressor, discharge the system and recover
Fuel Line Removal Tool T93T-9550-AH refrigerant as outlined in Section 12-00.
Disconnect the A I C manifold and tube (190734)
Removal at the A I C compressor mounting bracket.
If the cylinder head (6049) is to be replaced, follow the Remove A I C compressor from A I C compressor
procedures under Cylinder Head Disassembly and mounting bracket. Remove the A I C compressor
Assembly. Transfer all valves, springs, etc., to the new mounting bracket from engine.
cylinder head. If these are worn, the complete head 13. Remove the upper intake manifold as outlined in
assembly may have to be replaced. Clean and inspect this section.
all parts, reface the valves and check valve guide
clearances before assembling the used parts to the 14. Remove the valve cover (6582). Loosen the
new cylinder head. Refer to Section 03-00. rocker arm bolts so that the rocker arms (6564)
can be rotated to one side. Refer to Valve Cover
1. Drain the cooling system and the crankcase. and Rocker Arm procedure in this section.
Remove the air cleaner outlet tube (98659).
Remove A I C compressor (19703) and A I C 15. Remove the push rods (6565) in sequence and
condenser core (19712). Refer to Section 03-05 identify them so that they can be installed in their
and to the applicable section in Group 12 ih the original positions.
Body, Chassis Service Manual.
2. Disconnect the battery ground cable (14301).
Disconnect the heater water hose (18472) from
the water pump (8501) and water outlet
connection.

ALL RIGHTS RESERVED
16. Disconnect the distributor to spark plug wires at 2. Check the flatness of the cylinder head and
the spark plugs (12405) using Spark Plug Wire cylinder block gasket surfaces as outlined in
Remover T74P-6666-A. Section 03~0.
3. Install secondary air injection manifold and
secondary air injection check valve (if removed).
4. Position the head gasket (6051) over the cylinder
head to block dowels (6A008) on the cylinder
block.
5. Install lifting eyes on the cylinder head and use a
floor crane and lifting sling to lift the cylinder head
over the cylinder block. Lower it carefully until it is
((C_-
properly positioned on the cylinder block and
cylinder head to block dowels. Remove the hoist
and lifting eyes.
6. NOTE: Inspect cylinder head bolt for stretch. If
TWIST AND PULL stretch is found, replace cylinder head bolts.
B3496·E Coat the threads of the cylinder head bolts with
engine oil. Install the bolts.
17. Remove the cylinder head bolts. Install the
cylinder head lifting eyes using Engine Lifting 7. NOTE: When cylinder head bolts have been
Bracket T70P-6000. Position a floor crane and tightened, it is not necessary to retighten the
attach the hoist and lifting sling to the lifting eyes bolts after extended operation.
using Rotunda Universal Load Positioning Sling lighten the bolts in the numerical sequence
014-00036 and Rotunda Floor Crane 014-00133 shown. Bolts are tightened in three steps.
or equivalents. Lift the cylinder head and lower
intake manifold (9424) and exhaust manifold • lighten all bolts in numerical sequence to
assemblies off the engine. Do not pry between 34-47 N·m (25-35Ib-ft).
the cylinder head and cylinder block (6010) • Tighten all bolts in numerical sequence to
as the gasket surfaces may become 65-74 N·m (48-55Ib-ft).
damaged. Gently tapping the cylinder head
using a heavy plastic or rawhide hammer will help • Rotate all bolts in numerical sequence an
free up the cylinder head and ease removal. additional 80-100 degrees.
18. Remove secondary air injection manifold (98445) Cylinder Head Bolts Tightening Sequence
and secondary air injection check valve (9A487).
LOCATION FOR LOCATION FOR
5/16" - 18 LIFTING EYE 5/16" - 18 LIFTING EYE
SECONDARY
AIR INJECTION
MANIFOLD
98445
CHECK VALVE
r
9A487
TIGHTENTO
(16-19 LB-FT)
CYLINDER
I; HEAD
......
.~".~ ~ ASSEMBLY
6049
FRONT
~
..
NUT AND
FERRULE A10351·1A
ASSEMBLY
98471
TIGHTEN TO 8. Apply Multi-Purpose Grease DOAZ-19584-AA or
(14-16 LB-FT) equivalent meeting Ford specifications
FRONT OF ENGINE ESB-M 1C93-A to both ends of the push rods.
A21333-B Install the push rods in their original bores,
positioning the lower end of the push rod in the
Installation valve tappet sockets.
1. Clean the cylinder head and cylinder block gasket 9. Install valve cover and related parts. Refer to
surfaces. Clean the exhaust manifold and dual Valve Cover and Rocker Arm procedure in this
converter Y pipe gasket surfaces. section.

ALL RIGHTS RESERVED
03·01A·18 Engine, 4.9L Six-Cylinder 03-01A-18
10. Install the upper intake manifold as outlined in this 26. Install the radiator. Connect the lower radiator
section. hose (8286) to the water pump and the upper
11. Connect the distributor to spark plug wires to the radiator hose (8260) to the water outlet
correct spark plugs. connection. Install A/C condenser core.
12. Install the dual converter Y pipe lockwashers and 27. On a vehicle with an automatic transmission,
nuts. Tighten the nuts 34-49 N·m (25-36Ib-ft). connect the oil cooler lines.
13. NOTE: When the battery (10655) has been 28. Connect battery ground cable to battery.
disconnected and reconnected, some abnormal 29. Fill and bleed the cooling system. Refer to
drive symptoms may occur while the powertrain Section 03-03. Fill the crankcase with oil
control module relearns its adaptive strategy. The specified in Section 00-03. Operate the engine at
vehicle may need to be driven to relearn the fast idle and check all hose connections and
strategy. gaskets for leaks.
Connect battery to starter relay cable (14300) 30. Perform EEC Quick Test to check the function of
engine ground connections. the PCM system. Refer to Powertrain
2
14. Connect engine control sensor wiring and fuel Control/Emissions Diagnosis Manual.
charging wiring and related connectors. 31. On a vehicle with standard transmission, check
15. Connect engine gauge feed wire to powertrain for correct clutch operation.
control module. 32. On a vehicle with an automatic transmission, refer
16. Connect the brake vacuum line to the intake to Section 07-01A, 07-018 or 07-01C depending
manifold. on transmission. Check the fluid level and add as
required to bring it to the proper level on the fluid
17. Route and connect engine control sensor wiring level indicator (7A020).
and fuel charging wiring.
18. Install generator mounting bracket on engine and
tighten bolts and nuts to 30-40 N·m (22-30 Ib-ft).
19. Install secondary air injection pump on generator Crankshaft Front Seal
mounting bracket and tighten bolts to 30-40 N·m
(22-30 Ib-ft). SPECIAL SERVICE TOOL(S) REQUIRED
20. Install generator to bracket and tighten top bolt to Description Tool Number
30-40 N·m (22-30 Ib-ft). Tighten bolt toward Front Cover Seal Remover 170P-6B070-B
center of engine to 40-53 N·m (30-40 Ib-ft) and
Crankshaft Seal Installer / Cover Aligner 1881-6701-A
outside bolt to 30-40 N·m (22-30 Ib-ft).
21. Install A / C compressor mounting bracket to Removal
engine and tighten nuts to 54-71 N·m (40-53Ib-ft).
1. CAUTION: Release drive belt tensioner
Tighten two bolts to 30-40 N·m (22-30 Ib-ft).
(68209) slowly or damage to the drive belt
22. Install A/C compressor and power steering pump tensioner may occur.
brace, if equipped, and tighten bolts to 30-40 N·m
Remove the drive belt (8620) from the engine
(22-30 Ib-ft).
(6007).
23. If not equipped with air conditioning, install power
2. Remove the bolts attaching the fan shroud
steering pump brace and tighten bolts to 24-31
(8146) to the radiator.
N·m (18-23Ib-ft).
3. Remove the fan shroud. Remove the fan and fan
24. Install power steering pump with assembled
clutch (8A616) from the water pump shaft.
hoses and tighten bolts to 30-40 N·m (22-30
Ib-ft). 4. Remove the crankshaft pulley (6312) attaching
screw and washer. Install the puller on the
25. Install the water pump pulley, fan clutch (8A616),
crankshaft pulley and remove the crankshaft
fan and drive belt. Tighten the fan bolts to 16-24-
pulley.
N·m (12-18 Ib-ft).


ALL RIGHTS RESERVED
5. Place the Front Cover Seal Remover 3. Apply CLEAN engine oil or 50 weight oil only. DO
T70P-6B07Q-B onto the engine front cover NOT use grease on the crankshaft front seal
(6019) over the crankshaft front seal (6700). rubbing surface of the crankshaft pulley inner hub
Tighten the two through-bolts to force the Front to prevent damage to the crankshaft front seal.
Cover Seal Remover under the seal flange. Apply a 6mm (1 /4-inch) bead of silicone rubber
to inside of keyway of crankshaft pulley hub.
Install within five minutes.
4. Line up the crankshaft pulley keyway with the
key on the crankshaft. Install the crankshaft
pulley on crankshaft. Install the capscrew and
washer. Tighten the screw to 95-122 N·m (70-90
Ib-ft).
5. Install the drive belt.
6. Position the fan shroud over the water pump.
Install the fan and fan clutch. Install the fan shroud
FRONT COVER
SEAL REMOVER attaching screws.
TOOL NO.
T70P-6B070-B
A5765-18
Water Pump
6. Alternately tighten the four puller bolts one half
turn at a time. Pull the crankshaft front seal from Removal
the engine front cover. 1. Drain the cooling system. To prevent loss of
Installation coolant when draining the radiator (8005), attach
a hose on the radiator draincock (8115) and drain
1. Coat a new crankshaft front seal with CLEAN the coolant from the radiator into a clean
engine oil or 50 weight oil only. Place the sleeve container.
and crankshaft front seal onto the end of the
crankshaft and push it toward the engine until the To drain the radiator, open the radiator draincock
crankshaft front seal starts into the engine front located at the bottom of the radiator and remove
cover. the radiator cap (8100) or tank cap. The engine
(6007) has one drain plug located at the left rear
2. Place the installation screw, washer, nut and of the cylinder block.
Crankshaft Seal Installer / Cover Aligner
T88T-670 1-A onto the end of the ('rankshaft 2. CAUTION: Release drive belt tensioner
(6303). Thread the screw into the crankshaft. (68209) slowly or damage to the drive belt
Tighten the nut against the washer and tensioner may occur.
installation sleeve to force the crankshaft front Using 3/ 8-inch drive flex handle, lift the drive belt
seal into the engine front cover. Remove the tensioner away from the belt. Remove belt.
installation tool from the crankshaft. Release drive belt tensioner slowly.
3. Remove the fan, fan clutch (8A616), and water
pump pulley (8509) as outlined in Section 03-05.
CRANKSHAFT SEAL
I
INSTALLER/COVER ALIGNER
T88T-6701-A
4. Disconnect the heater water hose (18472) and
lower radiator hose (8286) at the water pump
(8501).
() 5. Remove the bolts attaching the water pump to
the cylinder block (6010). Remove the water
pump and engine front cover gasket (6020).
Installation
1. If required, remove the fittings from the old water
pump and install them on the new water pump.
Clean all gasket material from the mounting
surfaces of the water pump and cylinder block.
2. Position a engine front cover gasket, coated on
both sides with sealer, on the cylinder block.
A10352-e 3. Install the water pump. lighten bolts to 17-24 N·m
(12-18 Ib-ft).

ALL RIGHTS RESERVED
4. Connect the lower radiator hose and heater 8. Remove the front oil pan and engine front cover
water hose. Install the water pump pulley and fan. (6019) cover attaching screws. Loosen the first
Refer to Section 03-05. Fill and bleed the cooling six bolts on each side of the oil pan (6675).
system as outlined in Section 03-03. Install drive Lightly push oil pan down so it does not exert any
belt (8620) on engine. Run engine until it reaches upward force on the engine front cover, which
normal operating temperature. Operate the may affect front seal alignment.
engine and check for leaks. 9. Remove the engine front cover.
10. Using a sharp knife, cut the engine front cover
gasket (6020) at the edge of the water pump
(8501). Remove the part of the engine front cover
Engine Front Cover gasket nut retained by the water pump.
SPECIAL SERVICE TOOL(S) REQUIRED 11. Replace crankshaft front seal (6700) whenever
the engine front cover is removed.
Installation
Crankshaft Damper Remover T58P-6316-D
Front Cover Aligner T61 P-60 19-B 1. Clean engine front cover and cylinder block
Crankshaft Damper Replacer T52L-6306-AEE
(6010) gasket surfaces. Also, clean any oil on oil
pan gasket (6710) as it will be re-installed.
Removal 2. If the water pump was not removed, trim off the
1. Drain the cooling system as outlined in Section part of the engine front cover gasket that would
03-03. go under the water pump.
2. Remove the fan shroud (8146) and radiator 3. Coat engine front cover gasket surfaces of the
(8005) as outlined in Section 03-03. cylinder block and engine front cover with Perfect
Seal Sealing Compound B5A-19554-A or
3. Using a 3 I 8-inch drive flex handle, lift the drive equivalent meeting Ford specifications
belt tensioner pulley away from the drive belt ESE-M4G 115-A. Position a new engine front
(8620). Remove drive belt. Release drive belt cover gasket on the cylinder block.
tensioner (6B209) slowly.
4. NOTE: When applying RTV sealant, always use
4. If equipped, discharge air conditioning system the bead size specified and join the components
and recover refrigerant as outlined in Section within 15 minutes of application. After this amount
12-00. of time the sealant begins to set up and its sealing
5. Remove AIC compressor (19703) if equipped. effectiveness may be reduced.
6. Remove AIC compressor mounting bracket Apply RTV Silicone Rubber D6AZ-19562-AA or
(2882) with attached power steering pump BA or equivalent meeting Ford specifications
(3A674) and hoses and set out of the way. ESB-M4G92-A to the block I pan junction and a
small bead on oil pan gasket sealing surface of
7. Remove the screw and washer from the end of the engine front cover. This provides an additional
the crankshaft (6303) and remove the crankshaft seal between engine front cover and the used oil
pulley (6312) using Crankshaft Damper Remover pan gasket.
T58P-6316-D.
CRANKSHAFT DAMPER
REMOVER TOOL
T58P-6316-D
Al783·1A REINFORCEMENT
PLATES
6A674
A4872-D

ALL RIGHTS RESERVED
5. NOTE: lighten front cover screws before the oil 7. Install the washer and capscrew. lighten to
pan-to-front cover screws to obtain proper engine 177-203 N·m (130-150 Ib-ft).
front cover alignment. 8. Install A I C·compressor mounting bracket to
Position the engine front cover over the end of the engine and tighten nuts to 54-71 N·m (40-52
crankshaft and against the cylinder block. Start Ib-ft). lighten two bolts to 30-40 N·m (22-30 Ib-ft).
the cover and pan attaching screws. Slide the 9. Install AIC compressor, if equipped, and power
Front Cover Aligner T61 P-60 19-8 over the crank steering pump brace and tighten bolts to 30-40
stub and into the seal bore of the engine front N·m (22-30 Ib-ft).
cover. lighten attaching oil pan screws to 14-20
N·m (10-15 Ib-ft) and front cover screws to 17-24 10. If not equipped with air conditioning, install power
N·m (13-18Ib-ft). steering pump brace and tighten bolts to 24-31
N·m (18-23 Ib-ft).
11. Install power steering pump with assembled
hoses and tighten bolts to 30-40 N·m (22-30
Ib-ft).
12. Fill and bleed the cooling system. Use the
specified antifreeze mix. Refer to Section 03-03.
13. CAUTION: To avoid damage to the engine
(6007) due to entrance of foreign material
during repairs, engine oil must be changed
when repairs are completed.
Change the engine oil with proper quantity and
quality oil as specified in Section 00-03.
14. Operate the engine at fast idle and check for
y
coolant and oil leaks.
~~ A9715-1A Timing Gears

6. Lubricate the crank stub, crankshaft pulley hub CAUTION: To prevent possible damage to the
inside diameter and the seal rubbing surface with camshaft lobes, do not rotate the camshaft
clean engine oil or 50 weight oil only. DO NOT use (6250) or crankshaft (6303) in the engine without
grease on seal. Apply a 6mm (1 14-inch) bead of the timing gears installed.
silicone rubber to inside of keyway of crankshaft Camshaft Gear
pulley hub. Align the crankshaft pulley keyway
with the key on the crankshaft and install the
crankshaft pulley using Crankshaft Damper
Replacer T52L-6306-AEE. Description Tool Number
Camshaft Gear Puller T82T-6256-A
Camshaft Gear Replacing Adapter T65L-6306-A
Removal
1. Drain the cooling system and crankcase.
2. Remove the engine front cover (6019) following
the procedures under Engine Front Cover.
3. Check the camshaft end play, the timing gear
backlash and the timing gear runout. Refer to
Section 03-00.
CRANKSHAFT DAMPER
REPLACER
T52L-6306-AEE A9716-1B
1995 F-150. F-250. F-350. Bronco. F-Super Duty Powertrain. Drivetrain July 1994

ALL RIGHTS RESERVED
4. Crank the engine (6007) until the timing marks

are aligned as shown.
TIMING
MARKS
5. Install the Camshaft Gear Puller T82T-6256-A as

shown and remove the camshaft gear.
2. Install the engine front cover and related parts
following the procedures under Engine Front
Cover.
3. Fill crankcase with oil specified in Section 00-03.
Fill cooling system as outlined in Section 03-03.
Start the engine and adjust the ignition timing as
outlined in Section 03-07A. Operate the engine at
fast idle and check all hose connections and
gaskets for leaks.
Crankshaft Gear
A3017·F Description Tool Number
Installation Crankshaft Damper Replacer T52L-6306-AEE
If the camshaft end play, timing gear backlash and / or
timing gear runout were excessive, make the Removal
necessary corrections before installing the camshaft 1. Drain the cooling system and crankcase. Remove
gear. the radiator (8005). Refer to Section 03-03.
1. . Make sure the camshaft sprocket spacer (6265) 2. Remove the engine front cover (6019) as outlined
and camshaft thrust plate (6269) are properly in this section.
installed. Align the gear keyway with the key and
install the camshaft sprocket on the camshaft 3. Crank the engine until the timing marks are
using Camshaft Gear Replacing Adapter aligned.
T65L-6306-A. Make sure that the timing marks
line up on the.camshaft and crankshaft gears.
TIMING
MARKS

ALL RIGHTS RESERVED
4. Use Crankshaft Damper Remover T58P-6316-D Camshaft

and remove the crankshaft gear. Remove the key
from the crankshaft (6303). SPECIAL SERVICE TOOL(S) REQUIRED

The camshaft (6250) and related parts are shown in

the following illustration.
CRANKSHAFT DAMPER
REMOVER-T58P-6316-0
A10358-18
Installation
A10354-B
1. Install the key in the crankshaft keyway. Install
the crankshaft gear using the Crankshaft Damper
Replacer T52L-6306-AEE. Make sure timing Part
marks are aligned properly on the camshaft and Item Number Description
crankshaft gears.
1 6265 Camshaft Sprocket Spacer
2 6261 Camshaft Front Bearing
3 391170-5 Key, 3/ 16xO.75
4 6262 Camshaft Front Intermediate
Bearing
5 6262 Camshaft Rear Intermediate
Bearing
6 6261 Camshaft Rear Bearing
7 376809-5 Camshaft Rear Bearing
Cover
8 6250 Camshaft
9 6269 Camshaft Thrust Plate
10 45964 Bolt, 5/ 16-18 x 0.75
11 6256 Camshaft Sprocket
(12-18 Lb-Ft)
CRANKSHAFT DAMPER
REPLACER-T52L-63Q&.AEE Removal
A10369-1a 1. Drain the cooling system and the crankcase.
2. Replace the crankshaft front seal (6700). Install 2. Remove the fan shroud (8146) and radiator
the engine front cover following the procedures (8005), valve tappets (6500) and engine front
under Engine Front Cover in this section. cover (6019), following the procedures given in
3. Install the radiator. Refer to Section 03-03. this section and Section 03-03.
4. Fill crankcase with oil specified in Section 00-03. 3. Disconnect primary wire at the coil. Remove the
Fill cooling system as outlined in Section 03-00. distributor (12127) following the procedure in
Start the engine (6007) and check all gaskets Section 03-07A.
and hose connections for leaks. Adjust the 4. Check the camshaft end play, the timing gear
ignition timing as outlined in Section 03-07A to backlash and the timing gear runout. Refer to
specifications on the Engine Emission Control Section 03-00.
Decal.

ALL RIGHTS RESERVED
5. Turn the crankshaft (6303) to align the timing Installation

marks as shown. If the camshaft end play, timing gear backlash and / or
timing gear runout were excessive, make the
necessary corrections before installing the camshaft.
1. Oil the camshaft bearing journals and ~pply
Multi-Purpose Grease DOAZ-19584-AA or
TIMING
MARKS equivalent meeting Ford specifications
ESB-M 1C93-A to all the lobes.
2. Assemble key, camshaft sprocket spacer and
camshaft thrust plate to camshaft. Align the gear
keyway with the key and install the camshaft
gear on the camshaft using Camshaft Gear
Replacing Adapter T65L-6306-A.
6. Remove the camshaft thrust plate screws.

Remove the camshaft gear using Camshaft Gear
Puller T82T-6256-A, as shown. Remove the key,
camshaft thrust plate (6269) and camshaft
sproc~et spacer (6265). Remove the camshaft.
Avoid damaging the camshaft bearings or
lobes during removal.
CAMSHAFT THRUST
~-- PLATE SCREW
~
C
,
c:: 3. Install the camshaft, camshaft sprocket and
camshaft thrust plate as an assembly, making
[ sure that the timing marks are in alignment. Use
c care to avoid bearing damage.
c 4. Tighten the crankshaft thrust plate attaching
1)
screws to 16-24 N·m (12-18 Ib-ft).
5. Crank the engine (6007) until the timing marks
are aligned. Do not turn the crankshaft again
until the distributor is installed.
/' A10356-1A
6. Clean the engine front cover and engine gasket
surfaces. Install a new crankshaft front seal
(6700) in the engine front cover if necessary.
Clean the crankshaft pulley (6312) and inspect it.
Refer to Section 03-00. Install the engine front
cover and crankshaft pulley, valve tappets and
radiator, following the installation procedures
given in this section and Section 03-03.
Install the distributor. Refer to Section 03-07A.
With the rotor at No. 1 firing position, align the
stator armature tooth exactly with the armature
tooth prior to tightening the hold-down clamp
(12270).
7. Fill engine crankcase with oil specified in Section
00-03. Fill cooling system as outlined in Section
03-03.
A3017-F 8. Start the engine and check for oil, coolant and
fuel leaks. Adjust the ignition timing.
ALL RIGHTS RESERVED
Exhaust Manifolds
Removal
1. Disconnect battery ground cable (14301).
2. Disconnect the inlet air hose at the crankcase
vent filter (6A768). Remove the air cleaner outlet
tube (98659).
3. Remove the accelerator control splash shield
(9E766). Disconnect the accelerator cable
(9A758) at the throttle body (9E926). Position
the accelerator cable out of the way.
4. Disconnect engine control sensor wiring
(12A581) from powertrain control module
(PCM)( 12A650).
5. On SFI engines, disconnect two heated oxygen
sensors (H02S)(9F472).
6. Disconnect the fuel lines from the fuel injection
supply manifold (9D280) with Fuel Line Removal
Tool T93T-9550-AH. Do not bend the fuel lines.
7. Remove the upper intake manifold (9424) and
throttle body.
8. Disconnect all the vacuum lines. Label the lines
so they are re-installed properly.
9. Remove two clips and intake manifold shield VIEWZ
A24048-A
(9471).
10. Using a 3/ 8-inch flex handle, rotate drive belt
tensioner (68209) and remove drive belt (8620). Part
11. Disconnect generator wiring.
1 10300 Generator
12. Remove two screws, and generator
2 8509 Water Pump Pulley
(GEN)(10300).
3 380288-52 Screw, 5/ 16-24 x 0.85
13. Disconnect air pump hoses. 4 390785-536 Screw, 3/8-16 x 1.25
14. Remove three screws and secondary air injection 5 391319-52 Bolt, 7/16-14 x 5.5
pump pulley (98447). 6 3191314-52 Bolt, 3/8-16 x 5.25
15. Remove two screws and secondary air injection 7 56561-82 Bolt, 7/ 16-14 x 1.25
pump (AIR pump)(9A486). 8 N802493-82 8crew; M6-1.0 x 16
16. Remove nut, three screws, and generator 9 98447 Secondary Air Injection
Pump Pulley
mounting bracket (10153).
10 9A486 Secondary Air Injection
Pump
11 56540-836 Bolt, 3/8-16 x 1.0
12 56545-82 Bolt, 3/8-16 x 2.25
13 382802-52 Nut, 3/8-16
(17-23 Lb-Ft)
(41-54 Lb-Ft)
(54-71 Lb-Ft)
D - Tighten to 16-21 N·m
(12-15 Lb-Ft)
E - Tighten to 55-74 N·m
(41-54 Lb-Ft) Refer to
procedure in text.
17. Disconnect the dual converter Y pipe (5F250)

and EGR valve to exhaust manifold tube (90477)
from the exhaust manifolds (9430).
18. Disconnect the power brake vacuum line.

ALL RIGHTS RESERVED
19. Remove manifold, rear exhaust manifold and 10. Connect power brake vacuum line.
lower intake manifold to the cylinder head (6049). 11. Connect dual converter Y pipe to the front and
Lift the manifolds from the engine (6007). rear exhaust manifolds. lighten lockwashers and
Remove and discard the gaskets. nuts to 34-49 N·m (25-36 Ib-ft).
Installation 12. Install generator mounting bracket and three bolts
1. Clean the mating surfaces of the cylinder head, finger tight. Install nut finger tight.
front exhaust manifold, rear exhaust manifold, a. lighten bottom rear bolt to 55-74 N·m (41-54
lower intake manifold, and upper intake manifold. Ib-ft).
2. NOTE: The EGR valve to exhaust manifold tube is b. lighten center bolts to 55-74 N·m (41-54
only on the rear exhaust manifold. Ib-ft).
If the rear manifold is to be replaced, remove the c. lighten nut to 55-74 N·m (41-54Ib-ft).
tube fittings from the discarded manifold as
required. d. lighten bottom front bolt to 55-74 N·m (4 1-54
Ib-ft).
3. On SFI engines, if either exhaust manifold is to be
replaced, remove the heated oxygen sensor from 13. Install secondary air injection pump and tighten
the old manifold and install in the new one. bolts to 55-74 N·m (41-54 Ib-ft).
4. Make sure dowel pin is in place. 14. Install secondary air injection pump pulley and
tighten screws to 16-21 N·m (12-15 Ib-ft).
5. Install rear exhaust manifold with bolts in holes 16
and 15. lighten bolts to 30-43 N·m (22-32Ib-ft). 15. Connect air pump hoses.
6. Install front exhaust manifold and lifting eye with 16. Install generator and tighten bottom screw to
stud in hole 13 and bolt in hole 14. Snug stud and 72-97 N·m (54-71 Ib-ft). lighten top screw to
tighten bolt to 30-43 N·m (22-32 Ib-ft). " 55-74 N·m (4 1-54 Ib-ft).
7. Install intake manifold gasket (9439) over dowel 17. Connect generator wiring.
pin and line up port openings in the cylinder head 18. Position drive belt.
and intake manifold gasket. 19. Using 3/ a-inch flex handle, rotate drive belt
8. Install the lower intake manifold onto dowel pins, tensioner and place accessory drive belt. Slowly
then install remaining bolts. release drive belt tensioner onto drive belt
9. lighten bolts to 30-43 N·m (22-32 Ib-ft) in tensioning drive belt.
numerical sequence shown.
..
FRONT OF ENGINE
A10704-1A
ALL RIGHTS RESERVED
20. Install heat shield and two clips.

Part
Upper Intake Manifold
~ 8 9424
FRONT OF ENGINE 21. Reconnect all vacuum lines.
22. Install the upper, intake manifold and throttle body
as outlined in this section.
23. Connect fuel lines to fuel injector supply manifold.
24. On SFI engines, connect two heated oxygen
sensors.
HEATED
OXYGEN
SENSOR
9F472
REAR EXHAUST
MANIFOLD
9431
3
FRONT EXHAUST
A24049-A MANIFOLD
9430
Part HEATED OXYGEN SENSORS,

SFI EQUIPPED ENGINES
Item Number Description A24050-A
1 - Runner Number 2
(Part of 9424) 25. Connect engine control sensor wiring to
2 9471 Intake Manifold Shield powertrain control module.
3 390717-556 Spring Clip 26. Connect the accelerator cable to the throttle
4 - Runner Number 3 body.
(Part of 9424)
5 - Runner Number 4 27. Install accelerator control splash shield.
(Part of 9424) 28. Install air cleaner outlet tube and PVC air inlet
6 - Runner Number 5 hose at the crankcase vent filter.
(Part of 9424)
7 9424 Lower Intake Manifold
(Continued)

ALL RIGHTS RESERVED
FRONT OF ENGINE
~
5 4
SECTION B VIEW A
A24051-A
Part Part
1 390754 Screw, 3/8-18 x 1~25 9 390530 Bolt, 3/8-16 x 1.31
2 9424 Lower Intake Manifold 10 9431 Rear Exhaust Manifold
3 9439 Intake Manifold Gasket 11 9F485 EGR Valve Tube to Manifold
4 6049 Cylinder Head Connector
5 - Dowel Pin 5/ 16 x 1.00 12 - Hole For Heated Oxygen
(Part of 56049) Sensor, used on California
Certified Vehicles with E40D
6 9430 Front Exhaust Manifold Transmission Only
7 17A084 Lifting Eye A - Refer to Text for Tightening
8 391402 Stud, 3/8-16 x 3.57 Instructions
(Continued)
Oil Pan and/or Oil Pump Screen Cover and 3. Remove the engine front support
Tube insulator-to-support bracket nuts and washers on
both supports. Raise the front of the engine
Removal (6007) with a transmission jack and wood block
1. Drain the crankcase and the cooling system. and place 25.4mm (1-inch) thick wood blocks
between the front engine support insulator (6038)
2. Raise the vehicle on a hoist. Disconnect the and front engine support brackets (6028). Lower
battery to starter relay cable (14300) at the the engine and remove the transmission jack.
starter motor ( 11002) and remove the attaching
bolts and starter motor. 4. Remove the oil pan attaching bolts and lower the
oil pan (6675) to the crossmember front frame.
ALL RIGHTS RESERVED
5. Remove two bolts securing oil pump (6600) to

cylinder block (6010). Remove nut securing oil
pump screen cover and tube (6622) and drop into
oil pan.
6. Remove oil pan and oil pan gasket (6710) from
vehicle.
7. Remove oil pump from oil pan.
8. Remove oil pan gasket from cylinder block or oil
pan.
Installation
1. Clean cylinder block and oil pan flanges.
2. Set oil pump and assembled oil pump screen
cover and tube in oil pan.
3. Apply WSE-M4G323-A3 sealer to parting lines
between rear main bearing cap and cylinder
block, and between engine front cover (6019)
and cylinder block.
4. Apply a suitable pressure-sensitive adhesive to
cylinder block flange and oil pan gasket. Make
sure oil pan gasket is positioned in rear main
FRONT OF
bearing cap groove and tucked into cap-to-block ENGINE
slot.
~
5. Position oil pan on crossmember front frame.
6. Raise oil pump into position and start bolts. Start A5092·H
oil pump screen, cover, and tube nut.
7. lighten oil pump bolts to 17-24 N·m (12-18Ib-ft). Part
lighten oil pump screen, cover, and tube nut to Item Number Description
30-43 N·m (22-32 Ib-ft). 1 6A674 Oil Pan Flange
8. Position oil pan on cylinder block flange. Reinforcement (RH)
2 390674 Screw
9. Install four bolts in positions A as shown and
3 390674 Screw
hand-tighten.
4 390674 Screw
10. Install the rest of the bolts and tighten to 20-23 5 390674 Screw
N·m (15-17 Ib-ft) except for bolt in position C.
6 390674 Screw
lighten bolt in position C to 21-27 N·m (15-20
Ib-ft). 7 390674 Screw
Reinforcement (LH)
9 390674 Screw
10 6701 Crankshaft Rear Oil Seal
11 6710 Oil Pan Gasket
12 6675 Oil Pan Assembly
A - Install First and
Hand-Tighten
B - Install After Bolts A and
Tighten ALL to 20-23 N·m
(15-17 Lb-Ft)
(16-20 Lb-Ft)
11. Raise the engine with a transmission jack and

remove the wood blocks from the front engine
support brackets. Lower the engine until the front
engine support insulators are positioned on the
front engine support brackets. Install the washers
and nuts on the insulator studs and tighten the
nuts to 73-100 N·m (54-74Ib-ft).
12. Install the starter motor ( 11 00 1) and connect the
starter cable.
ALL RIGHTS RESERVED
13. Lower the vehicle. Install the radiator (8005).

Refer to Section 03-03. Part
14. Install the upper intake manifold (9424) and
throttle body (9E926). 3 6622 Oil Pump Screen Cover and
Tube
15. Install the oil pan drain plug (6730). Fill the 4 391378 Screw, 5/ 16-18 x 1.13
crankcase with oil specified in Section 00-03. Fill
5 6626 Oil Pump Inlet Tube Gasket
cooling system as outlined in Section 03-03.
6 - Dowel (Part of 6600)
16. Start the engine and check for coolant and oil 7 - Number 5 Main Bearing Cap
leaks. Stud (Part of 6010)
8 6600 Oil Pump
A - Tighten to 17·24 N·m
(12-18 Lb-Ft)
Oil Pump B - Tighten 30-43 N·m
(22-32 Lb-Ft)
Removal
1. Remove the oil pan (6675) following the
procedures under Oil Pan, Removal.
2. Lift oil pump (6600) out of oil pan. Remove oil Crankshaft Main Bearings
pump screen cover and tube (6622).
Installation
1. Prime the oil pump by filling the inlet opening with
oil and rotating the oil pump intermediate shaft Main Bearing Insert Tool TOOL-6331-E
(6A618) until oil emerges from the outlet opening.
NOTE: If crankshaft main bearings (6333) need to be
2. Assemble oil pump inlet tube gasket (6626) and replaced, crankshaft (6303) should be removed to
oil pump screen cover and tube to oil pump and check crankshaft journals for damage. Refer to
tighten screws to 17-24 N·m (12-18Ib-ft). Section 03-00 for inspection procedures.
3. Set oil pump in oil pan and install oil pan as Do not file or lap bearing caps or use shims to
outlined in this section. obtain the pr~per bearing clearance.
Bearings are available for service in standard sizes or
FRONT OF ENGINE .010 and .020 inch undersize. Refer to the Parts
®1 .. Catalog for the available sizes. Undersize bearings are
available for use on journals that have been refinished.
If the rear main bearing is to be replaced, it will be
necessary to remove the engine, install it on a work
stand, replace the rear main bearing and replace the
crankshaft rear oil seal (6701).
Removal
1. Drain the crankcase. Remove the oil pan (6675),
oil pump (6600) and oil pump screen cover and
tube (6622) following the procedure in this
section.
2. NOTE: Loosen all main bearing caps until just
finger-tight. This will loosen the crankshaft and
ease installation of new bearings.
Replace one crankshaft main bearing at a
time, leaving the other bearings securely
fastened. Remove the main bearing cap to which
new bearings are to be installed.
A5767-e
Part
1 391378 Screw, 5/ 16-18 x 1. 13
2 33711 Nut
(Continued)

ALL RIGHTS RESERVED
3. Insert Main Bearing Insert Tool TOOL-6331-E in 2. To install the upper main bearing, place the plain
the oil hole in the crankshaft journal. end of the bearing over the shaft on the locking
tang side of the cylinder block and partially install
the bearing so that Main Bearing Insert Tool
TOOL-6331-E can be inserted in the oil hole in the
crankshaft journal. With tool positioned in the oil
hole, rotate the crankshaft slowly in the opposite
direction of engine rotation until the bearing is
seated. Remove the tool.
3. Check bearing clearance as outlined in Section
03-00.
4. NOTE: Select-fit the bearing for proper
clearance. Refer to Fitting Main and Connecting
Rod Bearings in Section 03-00.
After the bearing clearance has been found within
specifications, apply a light coat of engine oil to
the journal and bearings. Then, install the bearing
cap.
MAIN BEARING CRANKSHAFT
INSERT TOOL-6331-E JOURNAL 5. Jighten the cap bolts to 82-94 N·m (60-69 Ib-ft).
A10383·1A 6. Repeat the procedure for the remaining bearings
that require replacement.
4. Rotate the crankshaft in the direction of engine
rotation to force the bearing out of the cylinder 7. If the thrust bearing cap (No.5 main bearing) has
block (6010). been removed, install it as follows:
5. Clean the crankshaft journal. When replacing Install the thrust bearing cap with the bolts
standard bearings with new bearings, first try to finger-tight. Pry the crankshaft forward against
obtain the proper clearance with standard the thrust surface of the upper half of the bearing.
bearings or a combination of a standard bearing Hold the crankshaft forward and pry the thrust
and a .010- or .020-inch undersize bearing. bearing cap to the rear. This will align the thrust
surfaces of both halves of the bearing. Retain the
Installation forward pressure on the crankshaft. Tighten the
The upper and lower bearing halves are not cap bolts to 82-94 N·m (60-69Ib-ft).
interchangeable. The upper half is drilled and
grooved to provide entry of oil.
1. Be sure bearings and surfaces are clean. Foreign
material under the inserts will distort the bearings
and cause premature wear.
Thrust Bearing Cap, Installation
PRY CRANKSHAFT FORWARD PRY CAP BACKWARD TIGHTEN CAP
A10384-B

ALL RIGHTS RESERVED
8. If the rear main bearing is replaced (on a work 3. Remove the oil pan following the procedure in this
stand), clean the mating surfaces of the bearing section. Remove the oil pump screen cover and
cap and the cylinder block with Ford Metal tube (6622) and the oil pump (6600).
Surface Cleaner F4AZ-19536-RA or equivalent 4. CAUTION: Never cut into the ring travel area
meeting Ford specifications WSE-M5B392-A. In excess of 0.74mm (1 /32 inch) when
9. NOTE: When applying RTV sealant, always use removing ridges.
the bead size specified and join the components Rotate the crankshaft (6303) until the piston to
within 15 minutes of application. After this amount be removed is at the bottom of the stroke and
of time the sealant begins to "set-up" and its place a cloth on the piston dome to collect the
sealing effectiveness may be reduced. cuttings. Remove any ridge and / or deposits from
Apply a 1.6mm (1 / 16-inch) bead of RTV sealer, the upper end of the cylinder bore with Cylinder
Silicone Rubber D6AZ-19562-BA or equivalent Ridge Reamer T64L-6011-EA. Follow the
meeting Ford specifications ESE-M4G 195-A in instructions furnished by the tool manufacturer.
each corner of the rear main bearing cap saddle 5. Make sure all the connecting rod caps are
the full length of the saddle. Be sure the main marked so that they can be installed in their
bearing is fitted and the cap bolts tightened original positions. Remove the connecting rod
to 82-94 N·m (60-70 Ib-ft) before Installing cap.
the new crankshaft rear 011 seal.
6. Push the connecting rod and piston assembly out
10. Clean the oil pump screen cover and tube. Prime the top of the cylinder with the hantjle end of a
the oil pump by filling the inlet opening with oil and hammer. Avoid damage to the crankshaft journal
rotate the oil pump intermediate shaft (6A618) or the cylinder wall when removing the piston and
until the oil emerges from the outlet opening. rod.
11. Install the oil pump and oil pan following the
procedure in this section. Installation
12. Fill crankcase with oil specified in Section 00-03. 1. Clean the oil pump screen cover and tube and the
Fill cooling system as outlined in Section 03-03. oil pan and cylinder block (6010) gasket
Start the engine (6007) and check for oil surfaces.
pressure. Operate the engine at fast idle and 2. Oil the piston rings, pistons and cylinder walls
check for oil and coolant leaks. with light engine oil.
3. Make sure pistons are Installed In the same
cylinders from which they were removed or
to which they were fitted. The connecting rods
Pistons and Connecting Rods (6200) and bearing caps are numbered from 1 to
6 beginning at the front of the engine (6007). The
SPECIAL SERVICE TOOL(S) REQUIRED number on the connecting rod and bearing cap
must be on the same side of rod when installing in
Description Tool Number the cylinder bore. If a connecting rod is ever
Cylinder Ridge Reamer T64L-6011-EA transferred from one cylinder block to another or
from one cylinder to another, new connecting rod
Removal bearings (6211) should be fitted and the
1. Drain the cooling system as outlined in Section connecting rod should be renumbered to
03-03. Remove oil pan drain plug (6730) and correspond with the new cylinder number.
drain oil pan (6675).
2. Refer to Cylinder Head, Removal in this section
and remove the cylinder head (6049) and related
parts.
1995 F-150, F-250, F-350, Bronco, F-Super Duty P.owertrain, Drivetrain July 1994
ALL RIGHTS RESERVED
4. Make sure the ring gaps (oil ring spacer A, oil ring 7. Rotate the crankshaft to the bottom of its stroke.
segment B, and compression ring C) are properly Then, push the piston all the way down until the
spaced around the circumference of the piston. connecting rod bearing seats on the crankshaft
Oil the rings, then install Piston Ring Compressor journal. Install the connecting rod cap. Tighten the
D81L-6002-C or equivalent on the piston. Make nuts to 55-61 N·m (40-451b-ft).
sure that the indentation in the dome of piston is 8. After the piston and connecting rod assemblies
toward the front. have been installed, check the connecting rod
• Push the piston into its bore with the handle side clearance using a feeler gauge on each
end of a hammer until it is slightly below the top crankshaft journal.
of the cylinder. Be sure to guide the connecting
rods to avoid damaging the crankshaft
journals.
,-------=\
~
~~
~~\~
oil and rotating the oil pump intermediate shaft
C (6A618) until oil emerges. from the outlet opening.
PISTON
Install the oil pump and the oil pump screen cover
6108 and tube. Install the oil pan and related parts as
A2811-C outlined in this section.
10. Refer to Cylinder Head, Installation, and install the
cylinder head and related parts. Adjust the valve
clearance as outlined in this section.
11. Fill and bleed the cooling system. Refer to
Section 03-03. Fill the crankcase with oil
specified in Section 00-03.
12. Start the engine and check for oil pressure.
Operate the engine at fast idle and check for oil
and coolant leaks.
13. Operate the engine until engine temperatures
have stabilized. Check and adjust the ignition
timing. Refer to Section 03-07A.
Connecting Rod Bearings

Removal
1. Drain the crankcase. Remove the oil pan (6675)
5. Check the clearance of each connecting rod and oil pump (6600) following the procedure in
bearing following the procedure under Fitting this section.
Main or Connecting Rod Bearing in Section
03-00.
6. After the connecting rod bearings have been
fitted, apply a light coat of engine oil to the
journals and connecting rod bearing.

ALL RIGHTS RESERVED
2. NOTE: If connecting rod bearings (6211) are to 3. NOTE: To check flywheel face runout or replac'e
be reused, identify them according to location so the flywheel ring gear (6384), refer to Section
that they can be installed in their original 03-00.
positions. Remove the flywheel attaching bolts and remove
Rotate the crankshaft (6303) until the connecting the flywheel (6375).
rod (6200) to which new bearings are to be fitted For installation, follow removal steps in reverse
is at the bottom of the stroke. Remove the order. Coat the threads of the flywheel attaching
connecting rod cap. Remove the bearing inserts bolts with oil-resistant sealer and install the bolts.
from the connecting rod and cap. Tighten in an opposing pattern to 102.. 115 N·m
3. Make sure the bearing inserts and the bearing (75-85 Ib-ft).
bore in the connecting rod and cap are clean.
Foreign material under the inserts will distort the
bearing and cause premature wear.
4. Clean the crankshaft journal. When replacing Mainshaft Bearing Roller
standard size bearings with new bearings, first
try to obtain the proper clearance with standard SPECIAL SERVICE TOOL(S) REQUIRED
size bearings. Refer to Section 03-00 for the
cleaning and inspection procedures. Description Tool Number
Puller T58L-101-B
Installation T74P-7137-A
Pilot Bearing Replacer
1. Install the bearing inserts in the connecting rod
and cap with the tangs fitted in the slots. A needle roller bearing and adapter assembly is used
as a pilot bearing on F-15Q-250-350 vehicles. It is
2. Pull the connecting rod down firmly on the
inserted directly into the crankshaft. The bearing and
crankshaft journal.
adapter assembly cannot be serviced separately. The
Check bearing clearance. Refer to Section pilot bearing can only be installed with the seal end of
03-00. the bearing facing the transmission (7003). The pilot
3. After the bearing clearance has been checked bearing is pregreased and does not require additional
and found OK or concern corrected, clean and lubrication. A new pilot bearing must be installed
apply a light coat of engine oil to the journal and whenever a transmission input bearing is removed. For
bearings. Install the connecting rod cap and additional information refer to Section 08-01.
tighten the nuts to 55-61 N·m (40-451b-ft).
4. Repeat the procedure for the remaining MAINSHAFT
connecting rods that require new connecting rod BEARING
ROLLER-7120
bearings.
5. Install the oil pan and oil pump following the
procedures under Oil Pan, Installation in this RECESS FOR
section. REMOVAL
TOOL
6. Fill the crankcase with oil specified in Section
00-03. Fill the cooling system. Refer to Section
03-03. Start the engine (6007) and check for oil
SEAL
pressure. Operate the engine at fast idle and
check for oil and coolant leaks.
C2981-e
Flywheel Removal
Removal 1. Remove the transmission, clutch pressure plate
(7563), and clutch disc (7550). Refer to Section
1. Remove the transmission (7003) following the 08-01.
procedure in the appropriate transmission section
in Group 07.
2. On a manual transmission, remove the clutch
pressure plate (7563) and cover assembly and
clutch disc (7550) following the procedure in
Section 08-01.
ALL RIGHTS RESERVED
2. Using Puller TS8L-101-B, remove the pilot 2. If equipped with manual transmission, remove
bearing. clutch assembly as outlined in Section 08-01.
3. Remove flywheel attaching bolts and remove rear
cap (main bearing) and flywheel (6375).
4. CAUTION: Use caution throughout this
procedure to avoid scratching or otherwise
damaging the crankshaft oil seal surface.
Use an awl to punch two holes in the crankshaft
rear oil seal (6701). Punch the holes on opposite
sides of the crankshaft (6303) and just above the
bearing cap-to-cylinder block split line. Install a
sheet metal screw in each hole. Use two large
screwdrivers or small pry bars and pry against
both screws at the same time to remove the
crankshaft rear oil seal. It may be necessary to
place small blocks of wood againsfthe cylinder
block (6010) to provide a fulcrum point for the pry
bars.
5. Clean the oil seal recess in the cylinder block and
main bearing cap. Inspect and clean the oil
seal contact surface on the crankshaft.
A10380-E
Installation
1. Using Pilot Bearing Replacer T74P-7137-A,
install the pilot bearing with the seal facing the
transmission so that the adapter is not
misaligned.
Installation
1. Coat the oil seal-to-cylinder block surface of the
crankshaft rear oil seal with oil Xo-SW3Q-aSp or
DSP or equivalent meeting Ford specifications
ESE-M2C153-E. Coat the seal contact surface of
the crankshaft rear oil seal and crankshaft with
A10361-B
heavy SF engine oil. Place crankshaft rear oil
2. NOTE: Care must be taken not to damage the seal on Rear Oil Seal Installer T89T-6701-AH
pilot bearing while the transmission input shaft is and, using hammer, tap into place until tool
being inserted into the pilot bearing during contacts face of cylinder block or bearing cap.
transmission installation. 2. Install flywheel. Tighten flywheel attaching bolts
Install the clutch pressure plate, clutch disc, and as follows:
transmission. Refer to section 08-01. a. First stage - 12-15 N·m (9-11Ib-ft).
b. Second stage - 68-74 N·m (50-55Ib-ft).
3. If equipped, install clutch as outlined in Section
Crankshaft Rear Oil Seal 08-01.
Removal
1. Remove the transmission (7003) as outlined in
Group 07.
ALL RIGHTS RESERVED
4. Install transmission as outlined in Section 07. 2. Remove the flywheel attaching bolts. Remove the
flywheel (6375) and the engine rear plate (7007).
3. Refer to core plug service procedures in Section
03-00 to remove the camshaft rear bearing
cover.
For installation, follow removal steps in reverse
order. Coat the flywheel bolts with pipe sealant
Teflon@ D8AZ-19554-A or equivalent meeting
Ford specification WSK-M2G350-A2 and tighten
in an opposing pattern to 102-115 N·m (75-85
Ib-ft).
Oil Filter
Removal
1. Place a drip pan under the oil filter. Unscrew the
A23871-A oil filter from the cylinder block (60.10) using Oil
Filter Wrench D79L-6731-A, -8 or equivalent.
Part Installation
1. Coat the gasket on the oil filter with oil. Place the
1 - Crankshaft Hub oil filter in position on the cylinder block.
(Part of 6303) Hand-tighten the oil filter until the gasket contacts
2 - Crankshaft Seal Bore the adapter face, then advance it one-half turn.
(Part of 6010)
3 6010 Cylinder Block 2. Operate the engine (6007) at fast idle and check
4 - Plug Bore (Part of 6010) for oil leaks. If oil leaks are evident, perform the
necessary repairs to correct the leakage. Check
Cover the oil level and fill the crankcase if necessary.
6 T89T-6701-AH Rear Oil Seal Replacer
8 - Metallic Side of Seal
(Part of 6266) Oil Level Indicator Tube
1. Open hood.
Camshaft Rear Bearing Cover 2. Remove oil level dipstick (6750).
Removal and Installation 3. Remove nut securing oil level indicator tube
bracket to valve pushrod cover retainer.
1. Remove the transmission (7003) and flywheel
housing. Refer to Section 07-01A, 07-018, or 4. Unscrew oil level indicator tube retaining nut and
07-01C, depending on transmission. On a manual remove oil level indicator tube (6754) from engine
transmission, remove the clutch pressure plate (6007).
(7563) and clutch disc (7550). Refer to Section
08-01.
ALL RIGHTS RESERVED
03-01A-37 Engine, 4.9L Six-Cylinder 03·01A-37
5. Reverse removal steps to install. Tighten oil level 7. Close hood.

indicator tube retaining nut to 20-24 N·m (15-17
Ib-ft). Tighten oil level indicator tube to valve
pushrod cover retainer nut to 4-5 N·m (35-44
Ib-in).
ENGINE
6010
•
FRONT OF ENGINE
A23875-A
A23872·A
Part
1 6750 Oil Level Dipstick REMOVAL AND INSTALLATION
2 370786-S8 Nuts, Stamped 15/ 16
3 6754 Oil Level Indicator Tube Engine Assembly
4 - Oil Level Indicator Tube
Retaining Nut (Part of 6754) SPECIAL SERVICE TOOL(S) REQUIRED
Bracket (Part of 6754) De8crlptlon Tool Number
6 6C517 Retainer Assembly Engine Lifting Bracket T70P-8000
7 6519 Valve Pushrod Cover Fuel Line Removal Tool T93T-9550-AH
The following engine removal and installation

procedures are for the engine (6007) only, without the
Sensors transmission attached.
Oil Pressure Sender Switch Removal

1. Drain the cooling system and the crankcase.
Removal and Installation Remove the hood (16612). Remove the air
1. Open hood (16612). cleaner outlet tubes (98659).
2. Disconnect oil pressure switch lead. 2. Disconnect the battery ground cable (14301).
3. Using suitable oil pressure sender socket, Disconnect the heater water hose (18472) from
remove oil pressure sensor (9278). the water pump (8501) and clutch pressure plate
(7563). Disconnect the fuel lines at the fuel
4. Start replacement oil pressure sensor by hand. injection supply manifold as outlined in Section
Using suitable oil pressure sender socket, tighten 03-Q4A.
to 11-24 N·m (8-181b-ft).
3. Remove the radiator (8005) and fan shroud
5. Connect oil pressure sensor. (8146). Refer to Section 03-03.
6. Start engine (6007) and check for leaks and oil
pressure gauge operation.
ALL RIGHTS RESERVED
4. NOTE: The fan clutch (8A616) hub has a 12. Raise the vehicle. Remove the starter motor
right-hand thread. ( 1100 1) (and the automatic transmission fluid
Remove the fan blade (8600), fan clutch, water filler tube bracket). Remove the engine rear plate
pump pulley (8509) and drive belt (8620) as upper right bolt.
outlined in Section 03-05. 13. On a vehicle with a manual transmission (7003),
remove all the flywheel housing lower attaching
bolts. Disconnect the clutch slave cylinder
(7A508).
14. On a vehicle with an automatic transmission,
remove the transmission housing cover (7986)
assembly. Remove the flywheel-to-converter nuts
and secure the torque converter (7902)
assembly in the housing.
15. Remove the transmission oil cooler lines from the
retaining clip at the engine. Remove the converter
housing-to-engine lower attaching bolts.
16. Remove the insulator-to-intermediate support
bracket nut from each engine front _support.
17. Lower the vehicle and position a transmission
jack, such as Rotunda 066-00017 or equivalent,
under the transmission to support it.
18. Remove the remaining flywheel or converter
SCREW AND WASHER
ASSEMBLV-57632-S2 housing-to-engine bolts.
(4 REQ'D) FAN CLUTCH
TIGHTEN TO
19. Attach Engine Lifting Bracket T70P-60OC and
8A616
16-24 N·m Rotunda Engine Sling 014-00036 or equivalent.
(12-18 FT-LB)
INSTALLATION 4.9L
ERENGINE A10702-e 20. Raise the engine slightly and carefully pull it from
the transmission. Lift the engine out of the
5. Disconnect the accelerator cable (9A758) at the chassis.
throttle body (9E926).
Installation
Disconnect power brake vacuum line at the intake
manifold (9424). 1. NOTE: If the engine will not properly mate to the
transmission after the crankshaft (6303) enters
6. Disconnect the exhaust manifolds (9430) from the transmission housing, turn the crankshaft
the dual converter Y pipe (5F250). Disconnect slowly (with the transmission in gear) until the
the battery to starter relay cable (14300) at the crankshaft splines mesh with the clutch disc
engine. Disconnect Secondary Air Injection splines.
system.
Lower the engine carefully into the chassis. Make
7. Disconnect the engine control sensor wiring sure the dowels in the block engage the holes in
(12A581) from powertrain control module the converter housing.
(PCM)( 12A650).
On a vehicle with an automatic transmission, start
8. Disconnect the engine gauge feed wire (14289) the torque converter pilot into the crankshaft.
at the ignition coil, engine coolant temperature Remove the retainer securing the torque
sensor (ECl sensor)( 12A648) and oil pressure converter in the housing.
sensor (9278). Position the engine gauge feed
wire out of the way. On a vehicle with a manual transmission, start the
input shaft (7017) into the clutch disc (7550). It
9. Remove the generator mounting bolts and may be necessary to adjust the position of the
position the generator (GENX10346) out of the transmission with relation to the engine if the input
way, leaving the wires attached. shaft will not enter the clutch disc.
10. Remove the power steering pump (3A674) from 2. Install the converter or flywheel housing upper
the mounting brackets and position it right side up attaching bolts. Remove the jack supporting the
and to one side, leaving the lines attached. transmission. Refer to Section 07-o1A, 07-o1B,
11. If equipped with an A / C compressor (19703), 07-01C, or 08-01, depending on transmission, for
discharge the air conditioner system as outlined torque specifications.
in Section 12-00 and disconnect the A / C manifold 3. Lower the engine onto the engine support(s) and
and tube assembly at the compressor. remove the lifting sling.
Disconnect vacuum signal line to the manifold
absolute pressure sensor (MAP sensor)(9F479). 4. Install the engine left and right support
Disconnect vacuum jumper harness to reservoir. insulator-to-intermediate support bracket
Remove purge lines from throttle body. Remove attaching nuts and washers. Tighten the nuts to
supply and return fuel lines with Fuel Line 73-100 N·m (54-74Ib-ft).lnstall the transmission
Removal Tool T93T-9550-AH. oil cooler line clip (7N291).
ALL RIGHTS RESERVED
5. Install the remaining converter or flywheel 14. Install the radiator and fan shroud. Connect the
housing attaching bolts. lower radiator hose (8286) to the water pump
6. Install the starter motor and connect the battery and the upper radiator hose (8260) to the water
to starter relay cable. Attach the automatic outlet connection. Connect the A/C manifold and
transmission fluid filler tube bracket, if so tube (190734). Refer to Section 03-03 for torque
equipped. specifications.
On a vehicle with an automatic transmission, On a vehicle with an automatic transmission,
install the transmission oil cooler lines in the connect the oil cooler lines. Refer to Section
transmission oil cooler line clip. 03-03 for torque specifications.
7. Install the exhaust manifold-ta-muffler inlet pipe 15. Install and adjust the hood.
lockwashers and nuts. lighten the nuts to 34-49 16. Fill and bleed the cooling system. Refer to
N·m (25-36Ib-ft). Section 03-03. Fill the crankcase with motor oil
8. NOTE: When the battery has been disconnected specified in Section 00-03. Operate the engine at
and reconnected, some abnormal drive fast idle and check all hose connections and
symptoms may occur while the powertrain gaskets for leaks.
control module relearns its adaptive strategy. 17. Perform EEC Quick Test to check the function of
The vehicle may need to be driven 10 miles or the EEC system, if so equipped. Refer to
more to relearn the strategy. Powertrain Control I Emissions Diagnosis
3
Connect battery to starter relay cable to engine Manual.
ground connections and the battery ground cable. 18. On a vehicle with a manual transmission, check
9. Connect engine control sensor wiring. for correct clutch operation.
10. On a vehicle with an automatic transmission, On a vehicle with an automatic transmission,
connect the transmission kickdown cable to the adjust the transmission control linkage. Refer to
throttle body. Section 07-05. Check the fluid level and add as
required to bring it to the proper level on the oil
Connect the accelerator cable to the throttle indicator.
body and install the accelerator control splash
shield (9E766). 19. Install the air cleaner outlet tube.
Reconnect power brake vacuum line to the intake
manifold vacuum outlet fitting and cap (9A474).
11. Connect the coil primary wire, oil pressure and Valve Cover and Gasket
coolant temperature sending unit wires, flexible
fuel line, heater hoses and the battery positive Removal
cable. 1. NOTE: The steps in this procedure are written
12. Install: assuming the engine has been "removed from the
vehicle as outlined in this section. For removal
• Secondary air injection pump (AIR and installation of these components with the
pump)(9A486) and tighten bolts to 30-40 N·m engine installed in the vehicle, refer to In-Vehicle
(4 1-54 Ib-ft). Service in this section.
• Generator (GENX10300) to generator Remove the upper intake manifold (9424) and
mounting bracket (10153) and tighten top bolt throttle body (9E926).
to 30-40 N·m (41-541b-ft). lighten bolt toward 2. Remove the positive crankcase ventilation valve
center of engine to 40-53 N·m (54-71 Ib-ft) and (PCV valve)(6A666) from the valve cover.
outside bolt to 30-40 N·m (41-541b-ft). Remove the crankcase vent filter (6A768).
• A I C compressor to A I C compressor mounting Remove the cover bolts and remove the valve
bracket (2882) and tighten to 18-23 N·m cover. Inspect the valve cover bolts for worn or
(24-31 Ib-ft). damaged seals under the bolt heads and replace
• Power steering pump to A I C compressor as necessary.
mounting bracket and tighten to 30-40 N·m Installation
(4 1-54 Ib-ft).
1. Clean the valve cover (6582) and the gasket
13. NOTE: The fan clutch hub has a right-hand surface of cylinder head (6049). Place the new
thread. valve cover gasket (6584) on cylinder head
Install the water pump pulley, fan clutch, fan and making sure that the tabs of the gasket face
drive belt. lighten the fan bolts to 16-24 N·m down toward the head. No sealer or adhesive is
(12-18 Ib-ft). necessary.

1995 F-150, F-250,F-350, Bronco, F-Super Duty Powertrain, Drivetrain July 1994
ALL RIGHTS RESERVED
03-0 1A-40 Engine, 4.9L Six-Cylinder 03-01A-40
2. Install the valve cover on the cylinder head. Make

sure the valve cover gasket seats evenly all
around the cylinder head. Partially tighten the
cover bolts in an opposing pattern, starting at the
middle bolts. Then tighten the bolts to 8-14 N·m
(70-124Ib-in) in the same sequence.
3. Install the positive crankcase ventilation valve in
the valve cover.
4. Install the upper intake manifold, throttle body
and EGR valve to exhaust manifold tube (90477).
NOTE: Perform other needed maintenance and
reinstall engine (6007) as outlined in this section.
Rocker Arm
Removal
1. Remove valve cover (6582) and valve cover Part
gasket (6584) as outlined in this section. Item Number Description
2. Remove the valve rocker arm bolt, rocker arm 1 390385 Bolt, 5/ 16-18 x 1.35
seat (6A528), and rocker arm (6564). If removing 2 6A528 Rocker Arm Seat
a pair of rocker arms, also remove rocker arm 3 6564 Rocker Arm
fulcrum guide (6A588). 4 6A588 Rocker Arm Fulcrum Guide
Installation 5 - Threaded Pedestal
(Part of 6049)
1. Apply Multi-Purpose Grease 00AZ-19584-AA or 6 - Refer to Valve Clearance
equivalent meeting Ford specification Adjustment Procedure in
ESB-M 1C93-A to the top of the valve stem. This Section
2. Apply Multi-Purpose Grease 00AZ-19584-AA or
ESB-M1C93-A to the rocker arm seat, the rocker
arm fulcrum guide, and the rocker arm seat Valve Spring, Retainer and Valve Stem Seal
socket in the rocker arm.
3. If removed, position the rocker arm fulcrum guide. SPECIAL SERVICE TOOL(S) REQUIRED
4. Install rocker arm, rocker arm seat, and bolt. Description Tool Number
5. Adjust the valve clearance following the Valve Spring Compressor T70P-6049-A
procedure under Valve Clearance Adjustment in Valve Stem Seal Replacer T87L-6571-BH
this section.
Broken valve springs (6513) or worn or damaged
6. Install valve cover as outlined in this section.
valve stem seals (6571) and valve spring retainer
(6514) may be replaced without removing the cylinder
head providing damage to the valves or valve seats
has not occurred.

ALL RIGHTS RESERVED
Removal 4. Remove the push rod (6565). Place a block of

1. NOTE: The steps in this procedure are written wood on top edge of valve spring retainer and tap
assuming the engine has been removed from the moderately with a hammer to unlock valve spring
vehicle as outlined in this section. For removal retainer keys (6518). Install the bolt and position
and installation of these components with the the Valve Spring Compressor T70P-6049-A as
engine installed in the vehicle, refer to In-Vehicle shown in the previous illustration. Compress the
Service in this section. valve spring and remove the valve spring retainer
keys, valve spring retainer and valve spring.
NOTE: Removal and Installation procedures Remove and discard the valve stem seal.
apply to both intake valve (6507) and exhaust
valve (6505). If air pressure fails to hold the intake valve in
the closed position during this operation, it
NOTE: For valve spring, retainer and valve stem can be presumed that the intake valve is not
removal with cylinder head removed, refer to seating or is damaged. If this condition
Cylinder Head Disassembly and Assembly in this occurs, remove the cylinder head (6049) for
section. further Inspection.
Remove the valve cover (6582). (Refer to Valve
Cover and Rocker Arm procedure in this section.)
Remove the applicable spark plug (12405).
2. Crank the engine (6007) until the applicable
piston is on TOC at the end of the compression
stroke.
3. Install a suitable Valve Holdup Air Adapter in the
spark plug hole and connect the air line.
SEAL
AIR LINE
A10099-B
5. If air pressure has forced the piston assembly to

the bottom of the cylinder, any removal of air
pressure will allow the intake valve to fall into the
cylinder. A rubber band, tape or string wrapped
around the end of the valve stem will prevent this
condition and will still allow enough travel to
check the intake valve for binds.
6. Inspect the valve stem for damage. Rotate the
intake valve and check the valve stem tip for
eccentric movement during rotation. Move the
intake valve up and down through normal travel in
the valve guide and check the stem for binds. If
the intake valve has been damaged, it will be
necessary to remove the cylinder head for
repairs. Refer to Section 03-00.
A10098-B 7. If the condition of the intake valve proved
satisfactory, hold the intake valve in the closed
position and apply air pressure within the
cylinder.
Installation
1. Install new valve spring retainers. Use a 5/ 8-inch
deep well socket and a light hammer or mallet to
seat the valve spring retainer on the valve guide
or use Valve Stem Seal Replacer T87L-6571-BH.
Place the valve spring in position over the intake
valve and install the valve spring retainer.
Compress the valve spring and install the valve
tool.

ALL RIGHTS RESERVED

ESB-M1C93-A to both ends of the push rod.
Install the push rod. Apply Multi-Purpose Grease
specification ESB-M 1C93-A to the top of the
valve stem.
3. Turn off the air and remove the air line and
adapter. Install the spark plug and connect the
distributor to spark plug wire. (Refer to Valve
Cover and Rocker Arm procedure in this section).
reinstall engine as outlined in this section.
Valve Tappet, Hydraulic

A10100-1A
I Installation
Description I Tool Number 1
I Spark Plug Wire Remover I T74P-6666-A 1 1. NOTE: Refer to Section 03-00 for the cleaning,
inspection and testing procedures.
Removal Clean the external surfaces of the valve tappets,
valve cover, cylinder head (6049) and cylinder
1. NOTE: The steps in this procedure are written
block (6010) gasket surfaces.
assuming the engine has been removed from the
vehicle as outlined in this section. For removal 2. Apply Multi-Purpose Grease DOAZ-19584-AA or
and installation of these components with the equivalent meeting Ford specification
engine installed in the vehicle, refer to In-Vehicle ESB-M 1C93-A to the cam lobe contact surface of
Service in this section. the valve tappets. Coat the rest of the valve
tappets with engine oil. Install the valve tappets
Remove the ignition coil attaching nuts and
with the tool shown under Removal.
position the ignition coil (12029) out of the way.
2. Remove the valve cover (6582). Refer to Valve
Cover procedure in this section.
ESB-M 1C93-A to both ends of the push rods.
3. Disconnect the distributor to spark plug wires at Install the push rods in sequence. Engage the
the spark plugs (12405) using Spark Plug Wire rocker arms with push rods and tighten the
Remover T74P-6666-A. Remove secondary high rocker arm bolts sufficiently to hold the push rods
tension wire from the coil. Remove the distributor in place. Make sure each push rods is
cap (12106), distributor adapter, and distributor properly seated in the valve tappet socket
to spark plug wire (12286) assembly. portion of the valve tappet.
4. Remove the valve tappet side cover. 4. Adjust the valve clearance. Refer to Adjustments
5. Loosen the rocker arm bolts until the rocker arms in this section.
(6564) can be disengaged from the push rods 5. Coat one side of a new valve pushrod cover
(6565). Remove the push rods. Remove the valve gasket with Perfect Seal Sealing Compound
tappets (6500) with the tool shown. If more than B5A-19554-A or equivalent meeting Ford
one push rod and valve tappet are removed, specification ES~-M4G 115-A oil resistant sealer,
place the parts in a rack so they can be installed and position to the pushrod cover. Install pushrod
in their original locations. cover. Alternately tighten the cover screws to
2.8-4.0 N·m (25-35Ib-in). Clean the valve cover.
Place the new valve cover gasket (6584) in the
valve cover. Install the valve cover. Refer to
Valve Cover and Gasket procedure in this
section.
6. Position the ignition coil on the cylinder block and
install the attaching bolt or nuts.
7. Install the distributor adapter, distributor cap and
distributor high tension wiring (12298).
reinstall engine (6007) as outlined in this section.

ALL RIGHTS RESERVED
Intake Manifold 4. Disconnect the PCV hose from the fitting, located
on the underside of the upper intake manifold
Upper (9424).
Removal 5. CAUTION: When disconnecting throttle
1. NOTE: The steps in this procedure are written cable from ball stud, use a screwdriver or
assuming the engine (6007) has been removed similar tool close to the ball stud to pry off.
from the vehicle as outlined in this section. For Removing by hand may damage the cable.
removal and installation of these components Remove the accelerator control splash shield
with the engine installed in the vehicle, refer to (9E766), and disconnect the accelerator cable
In-Vehicle Service in this section. (9A758) and speed control actuator (9A825).
If not already done, disconnect the electrical Position the cable away from the engine.
connectors at: 6. Disconnect the air cleaner outlet tube (9B659)
from the throttle body.
• EGR external pressure valve (9F483).
• throttle position sensor (TP sensor)(9B989).
tube (9D477) from the EGR external pressure
• idle air control valve (lAC valve)(9F715). valve and the rear exhaust manifold (9430).
• EGR EGR transducer (9J433) (if equipped). Remove the EGR valve to exhaust manifold tube
from the engine.
2. Disconnect the following vacuum connections:
• vacuum line at the EGR external pressure
valve.
• Evaporative Emission (EVAP) system lines to
the throttle.body (9E926) and evaporative
emission canister purge valve (EVAP canister
purge valves)(9C915), if equipped.
• vacuum lines to the upper intake manifold
vacuum outlet fitting and cap (9A474).
Labeling the hose locations with tape is
recommended to aid installation.
3. SFI engines, tag EGR transducer hoses. Remove
screws, EGR transducer and bracket, and
disconnect hoses.
INTAKE MANIFOLD VACUUM PCV

OUTLET FiniNG AND FiniNG
CAPS-9A474
Part
2 - Connector (Part of 90477)
3 9424 Intake Manifold (Upper)
4 9430 Exhaust Manifold (Rear)
5 90477 EGR Valve to Exhaust
Manifold Tube
(25-35 Lb-Ft)
8. Remove the secondary air bypass tube assembly

from the lower intake manifold by removing the
two nuts retaining the tube. Remove the nut
attaching the secondary air bypass valve bracket
to the lower intake manifold.
9. Remove the screw and washer assembly
V5844-E attaching the intake manifold support (9J444) to
the upper intake manifold.

ALL RIGHTS RESERVED
10. Remove the seven studs that retain the upper

intake manifold. FRONT OF ENGINE
~
V5847·F
Part
1 9E936 Gasket
2 45357 Nut5/16-18
3 9728 Bracket, Accelerator Cable
Assembly
6 56139 Screw arid Washer
Assembly 3/8-16 x .88
7 9J444 Intake Manifold Support
(14-20 Lb-Ft)
(22-32 Lb-Ft)
Installation
1. Position a new intake manifold upper gasket
(9H486) on the lower intake manifold, using the
Part lower manifold dowels to position the intake
Item Number Description manifold upper gasket.
1 9424 Intake Manifold (Upper) 2. Position the upper intake manifold onto the lower
2 9H486 Intake Manifold Upper intake manifold, using the dowels of the lower
Gasket intake to locate manifold holes. Install the seven
3 12A697 Intake Air Temperature studs to attach the upper intake manifold to the
Sensor lower intake manifold and hand-tighten.
4 390715 Stud (7 Req.)
5/16-18 x 2.505 3. lighten the seven studs attaching the upper
5 9424 Intake Manifold (Lower) intake manifold to the lower intake manifold to
16-24 N·m (12-181b-ft).
6 390659-5100 PCV Connector
7 9A474 Intake Manifold Vacuum 4. Position the upper intake manifold support onto
Outlet Fitting and Cap the boss of the upper intake manifold, located
A - Tighten to 16-24 N·m under the throttle body. Install the retaining screw
(12-18 Lb-Ft) and tighten to 30-43 N·m (22-32 Ib-ft).
5. Install the EGR valve to exhaust manifold tube
11. Remove the upper intake manifold and throttle
between the EGR external pressure valve and the
body from the lower intake manifold.
rear exhaust manifold. The tube is routed
between lower intake runners No.5 and No 6.
lighten both fittings to 34-47 N·m (25-35Ib-ft).
6". Connect the PCV hose to the fitting, located on
the valve cover (6582) under the upper intake
manifold plenum.

ALL RIGHTS RESERVED

IDLE AIR
CONTROL VALVE THROTTLE
ELECTRICAL POSITION
CONNECTOR SENSOR
98989
TWIST AND PULL

B3498-E
4. Remove the cylinder head bolts. Install the

V5842·F cylinder head lifting eyes using Engine Lifting
Bracket T70P-6000 in the locations shown.
Lower Position a floor crane and attach the hoist and
lifting sling to the lifting eyes using Rotunda
Removal and Installation Universal Load Positioning Sling 014-00036 and
NOTE: The lower intake manifold and exhaust Rotunda Floor Crane 014-00133 or equivalents.
manifolds must be removed together. To remove the Lift the cylinder head and lower intake manifold
lower intake manifold, follow the steps outlined for (9424) and exhaust manifold (9430) assemblies
removing the exhaust manifolds in this section. off the engine. Do not pry between the
cylinder head and cylinder block (6010) as
the gasket surfaces may become damaged.
Gently tapping the cylinder head using a heavy
Cylinder Head(s) plastic or rawhide hammer will help free up the
cylinder head and ease removal.
SPECIAL SERVICE TOOL(S) REQUIRED 5. Remove secondary air injection manifold (98445)
and secondary air injection check valve (9A487).
Engine Lifting Bracket T70P-6000 SECONDARY
AIR INJECTION
Fuel Line Removal Tool T93T-9550-AH MANIFOLD
98445
Removal CHECK VALVE
r
9A487
NOTE: The steps in this procedure are written TIGHTENTO
assuming the engine (6007) has been removed from (16-19 LB-FT)
the vehicle as outlined in this section. For removal and
installation of these components with the engine CYLINDER
installed in the vehicle, refer to In-Vehicle Service in " HEAD
this section. ...A'"................~ ASSEMBLY
6049
If the cylinder head (6049) is to be replaced, follow the
procedures under Cylinder Head Disassembly and
Assembly. Transfer all valves, springs, etc., to the new
cylinder head. If these are worn, the complete cylinder
head assembly may have to be replaced. Clean and NUT AND
inspect all parts, reface the valves and check valve FERRULE
ASSEMBLY
guide clearances before assembling the used parts to 98471
the new cylinder head. Refer to Section 03-00. TIGHTEN TO
1. Remove the valve cover (6582). Loosen the (14-16 LB-FT) ~
rocker arm (6564) bolts so that the rocker arms FRONT OF ENGINE
A21333-B
can be rotated to one side. Refer to Valve Cover
and Rocker Arm procedure in this section.
Installation
2. Remove the push rods (6565) in sequence and
identify them so that they can be installed in their 1. Clean the cylinder head and cylinder block gasket
original positions. surfaces. Clean the exhaust manifold and dual
converter Y pipe (5F250) gasket surfaces.
3. Disconnect the distributor to spark plug wires at
the spark plugs ( 12405) using Spark Plug Wire
Remover T74P-6666-A.

ALL RIGHTS RESERVED
2. Check the flatness of the cylinder head and 9. Install valve cover and related parts. Refer to
cylinder block gasket surfaces if the cylinder Valve Cover and Rocker Arm procedure in this
head was removed for a head gasket (6051) section.
replacement. Refer to Section 03-00. 10. Connect the distributor to spark plug wires to the
3. Install secondary air injection manifold and correct spark plugs.
secondary air injection check valve (if removed). 11. Install the generator mounting bracket (10153) on
4. Position the head gasket over the cylinder head engine. Install the AIC compressor (19703) and
to block dowels (6A008) on the cylinder block. power steering pump (3A674) on the A I C
5. Install lifting eyes on the cylinder head and use a compressor mounting bracket (2882).
floor crane and lifting sling to lift the cylinder head NOTE: Perform other needed maintenance and
over the cylinder block. Lower it carefully until it is reinstall engine as outlined in this section.
properly positioned on the cylinder block and
cylinder head to block dowels. Remove the hoist
and lifting eyes.
6. NOTE: Inspect cylinder head bolt for stretch. If Crankshaft Pulley and/or Crankshaft Front
stretch is found, replace cylinder head bolts. Seal
Coat the threads of the cylinder head bolts with
engine oil. Install the bolts. SPECIAL SERVICE TOOL(S) REQUIRED
7. NOTE: When cylinder head bolts have been Description Tool Number
tightened, it is not necessary to re-tighten the Front Cover Seal Remover T70P-6B070·B
bolts after extended operation.
Crankshaft Seal Installer / Cover Aligner T88T-6701-A
Tighten the bolts in the numerical sequence
shown. Bolts are tightened in three steps. NOTE: The steps in this procedure are written
assuming the engine (6007) has been removed from
• Tighten all bolts in numerical sequence to the vehicle as outlined in this section. For removal and
34-47 N·m (25-35 Ib-ft). installation of these components with the engine
• Tighten all bolts in numerical sequence to installed in the vehicle, refer to In-Vehicle Service in
65-74 N·m (48-55Ib-ft). this section.
• Rotate all bolts in numerical sequence an Removal
additional 80-100 degrees. 1. Remove the crankshaft pulley (6312) attaching
screw and washer. Install the puller on the
Cylinder Head Bolts nghtenlng Sequence crankshaft pulley and remove the crankshaft
pulley.
LOCATION FOR LOCATION FOR
5/16" - 18 LIFTING EYE 5/16" • 18 LIFTING EYE 2. Place the Front Cover Seal Remover
T70P-6B070-B onto the engine front cover
(6019) over the crankshaft front seal (6700).
Tighten the two through-bolts to force the Front
Cover Seal Remover under the seal flange.
FRONT
~
FRONT COVER
A10351·1A SEAL REMOVER
TOOL NO.
T70P-68070-B
equivalent meeting Ford specification A5765-18
ESB-M 1C93-A to both ends of the push rods.
Install the push rods in their original bores, 3. Alternately tighten the four puller bolts one half
positioning the lower end of the push rod in the turn at a time. Pull the crankshaft front seal from
valve tappet sockets. the engine front cover.

ALL RIGHTS RESERVED
Installation NOTE: Perform other needed maintenance and

1. Coat a new crankshaft front seal with CLEAN reinstall engine as outlined in this section.
engine oil or 50 weight oil only. Place the sleeve
and crankshaft front seal onto the end of the
crankshaft and push it toward the engine until the
crankshaft front seal starts into the engine front Water Pump
cover. NOTE: The steps in this procedure are written
2. Place the installation screw, washer, nut and assuming the engine (6007) has been removed from
Crankshaft Seal Installer / Cover Aligner the vehicle as outlined in this section. For removal and
T88T-6701-A onto the end of the crankshaft installation of these components with the engine
(6303). Thread the screw into the crankshaft. installed in the vehicle, refer to In-Vehicle Service in
Tighten the nut against the washer and this section.
installation sleeve to force the crankshaft front
seal into the engine front cover. Remove the
Removal
installation tool from the crankshaft. 1. Remove the bolts attaching the water pump
(8501) to the cylinder block (6010). Remove the
water pump and engine front cover gasket
CRANKSHAFT SEAL (6020).
T88T-6701-A I
Installation
1. If required, remove the fittings from the old water
pump and install them on the new water pump.
to Clean all gasket material from the mounting
surfaces of the water pump and cylinder block.
2. Position a new engine front cover gasket, coated
on both sides with sealer, on the cylinder block.
3. Install the water pump. Tighten bolts to 17-24 N·m
( 13-18Ib-ft).
A10352-C
3. Apply CLEAN engine oil or 50 weight oil only. DO Engine Front Cover
NOT use grease on the crankshaft front seal
rubbing surface of the crankshaft pulley inner hub SPECIAL SERVICE TOOL(S) REQUIRED
to prevent damage to the crankshaft front seal.
Apply CLEAN engine oil or 50 weight oil only. DO
NOT use grease on the front of the crankshaft for Crankshaft Damper Remover Tool T58P-6316-D
crankshaft pulley installation. Front Cover Aligner T61P-6019-B
Apply a 6mm (1/4-inch) bead of silicone rubber Crankshaft Damper Replacer T52L-6306-AEE
to inside of keyway of crankshaft pulley hub.
Install within five minutes.
4. Line up the crankshaft pulley keyway with the
key on the crankshaft. Install the crankshaft
pulley on crankshaft. Install the capscrew and
washer. Tighten the screw to 95-122 N·m (70-90
Ib-ft).

ALL RIGHTS RESERVED
Removal 2. Coat engine front cover gasket surfaces of the

cylinder block and engine front cover with Perfect
NOTE: The steps in this procedure are written
Seal Sealing Compound 85A-19554-A or
the vehicle as outlined in this section. For removal and equivalent meeting Ford specification
ESE-M4G115-A oil resistant sealer. Position a
installation of these components with the engine
new engine front cover gasket on the cylinder
installed in the vehicle, refer to In-Vehicle Service in
this section. block.
3. NOTE: When applying RTV sealant, always use
1. Remove the screw and washer from the end of
the crankshaft (6303) and remove the crankshaft the bead size specified on the package and join
pulley (6312) using Crankshaft Damper Remover the components within 15 minutes of application.
T58P-6316-D. After this amount of time the sealant begins to set
up and its sealing effectiveness may be reduced.
CRANKSHAFT DAMPER Apply RTV Silicone Rubber D6AZ-19562-AA or
REMOVER TOOL BA or eqUivalent meeting Ford specification
T58P-6316-0
ESB-M4G92-A to the block / pan junction and a
small bead on oil pan gasket sealing surface of
the engine front cover. This provides an additional
seal between engine front cover and the used oil
pan gasket.
A9713-1A
OIL PAN
2. Remove the front oil pan (6675) and engine front ~~--- GASKET
cover (6019) attaching screws. Loosen the first 6269
six bolts on each side of the oil pan. Lightly push
oil pan down so it does not exert any upward
force on the engine front cover, which may affect
front seal alignment.
3. Remove the engine front cover and discard the
engine front cover gasket (6020). Replace REINFORCEMENT
crankshaft front seal (6700) whenever the engine PLATES
front cover is removed. 6A674
A4872-D
Installation
1. Clean engine front cover and cylinder block
(6010) gasket surfaces. Also, clean any oil on oil
pan gasket (6710) as it will be reinstalled.

ALL RIGHTS RESERVED
4. NOTE: Tighten front cover screws before the oil 6. Install the washer and capscrew. Tighten to
pan-to-front cover screws to obtain proper engine 177-203 N·m (130-150 Ib-ft).
front cover alignment. NOTE: Perform other needed maintenance and
Position the engine front cover over the end of the reinstall engine as outlined in this section.
crankshaft and against the cylinder block. Start
the cover and pan attaching screws. Slide the
Front Cover Aligner T61 P-60 19-8 over the crank
stub and into the seal bore of the engine front TIming Gears
cover. lighten attaching oil pan screws to 14-20
N·m (10-15 Ib-ft) and front cover screws to 17-24 CAUTION: To prevent possible damage to the
N·m (13-18 Ib-ft). camshaft lobes, do not rotate the camshaft
(6250) or crankshaft (6303) in the engine without
the timing gears installed.
Camshaft Gear

~~
y Al795-1A
this section.
Removal
5. Lubricate the crank stub, crankshaft pulley hub 1. Remove the engine front cover (6019) following
inside diameter and the seal rubbing surface with the procedures under Engine Front Cover.
clean engine oil or 50 weight oil only. DO NOT use
grease on seal. Apply a 6mm (1 /4-inch) bead of 2. Check the camshaft end play, the timing gear
silicone rubber to inside of keyway of crankshaft backlash and the timing gear runout. Refer to
pulley hub. Align the crankshaft pulley keyway Section 03-00.
with the key on the crankshaft and install the 3. Crank the engine until the timing marks are
crankshaft pulley using Crankshaft Damper aligned as shown.
Replacer T52L-6306-AEE.
TIMING
MARKS

ALL RIGHTS RESERVED
4. Install the Camshaft Gear Puller T82T-6256-A as Crankshaft Gear

shown and remove the camshaft gear.
Crankshaft Damper Replacer T52L-6306-AEE

this section.
Removal
1. Remove the engine front cover (6019) as outlined
in this section.
A3017·F 2. Crank the engine until the timing marks are
aligned.
Installation
necessary corrections before installing the camshaft TIMING
gear. MARKS
1. Make sure the camshaft sprocket spacer (6265)

and camshaft thrust plate (6269) are properly
installed. Align the gear keyway with the key and
install the camshaft sprocket on the camshaft
(6250) using Camshaft Gear Replacing Adapter
T65L-6306-A. Make sure that the timing marks
line up on the camshaft and crankshaft gears.
3. Use Crankshaft Damper Remover T58P-6316-D

and remove the crankshaft gear. Remove the key
from the crankshaft (6303).
2. Install the engine front cover and related parts

following the procedures under Engine Front
Cover. CRANKSHAFT DAMPER
REMOVER-T58P-6316-0
NOTE: Perform other needed maintenance and A10358-1B
DAVE
1995 F-150, F-250, F-350, Bronco, F-Su'per Duty Powertrain, GRAHAM
Drivetrain INC.
- 2014
July 1994
ALL RIGHTS RESERVED
Installation
1. Install the key in the crankshaft keyway. Install
the crankshaft gear using the Crankshaft Damper
Replacer T52L-6306-AEE. Make sure timing
marks are aligned properly on the camshaft and
crankshaft gears.
Part
1 6265 Camshaft Sprocket Spacer
2 6261 Camshaft Front Bearing
3 391170-S Key,3/16xO.75
4 6262 Camshaft Front Intermediate
CRANKSHAFT DAMPER
Bearing
REPLACER-T52L-6306-AEE 5 6262 Camshaft Rear Intermediate
A10359-1B Bearing
2. Replace the crankshaft front seal (6700). Install 6 6261 Camshaft Rear Bearing
the engine front cover following the procedures 7 376809-S Camshaft Rear Bearing
under Engine Front Cover in this section. Cover
8 6250 Camshaft
NOTE: Perform other needed maintenance and Camshaft Thrust Plate
9 6269
10 45964 Bolt, 5/ 16-18 x 0.75
(12-18 Lb-Ft)
Camshaft
SPECIAL SERVICE TOOL(S) REQUIRED assuming the engine (6007) has been removed from
Camshaft Gear Puller T82T-6256-A installed in the vehicle, Refer to In-Vehicle Service in
Camshaft Gear Replacing Adapter T65L-6306-A this section.
The camshaft (6250) and related parts are shown in Removal
the following illustration. 1. Check the camshaft end play, the timing gear
backlash and the timing gear runout. Refer to
Section 03-00.
2. Turn the crankshaft (6303) to align the timing
marks as shown.
TIMING
MARKS
ALL RIGHTS RESERVED
3. Remove the camshaft thrust plate screws.

Remove the camshaft gear using Camshaft Gear
Puller T82T-6256-A, as shown. Remove the key,
camshaft thrust plate (6269) and camshaft
sprocket spacer (6265). Remove the camshaft.
Avoid damaging the camshaft bearings or
lobes during removal.
CAMSHAFT THRUST
PLATE SCREW
~
C
c,
[
c 3. Install the camshaft, camshaft sprocket and

c camshaft thrust plate as an assembly, making
sure that the timing marks are in alignment. Use
fJ
./ A10356-1A
4.
care to avoid bearing damage.
Tighten the crankshaft thrust plate attaching
screws to 16-24 N·m (12-18Ib-ft).
5. Crank the engine until the timing marks are
aligned. Do not turn the crankshaft again until
the distributor (12127) is installed.
6. Clean the engine front cover (6019) and engine
gasket surfaces. Install a new crankshaft front
seal (6700) in the engine front cover if necessary.
Clean the crankshaft pulley (6312) and inspect it.
Refer to Section 03-00. Install the engine front
cover and crankshaft pulley, valve tappets
(6500) and radiator (8005), following the
installation procedures given in this section and
Section 03-03.
7. Install the distributor. Refer to Section 03-07A.
With the rotor at No.1 firing position, align the
stator armature tooth exactly with the armature
tooth prior to tightening the hold-down clamp
A3017-F (12270).
Installation reinstall engine as outlined in this section.
necessary corrections before installing the camshaft.
Camshaft Bearings
1. Oil the camshaft bearing journals and apply
Multi-Purpose Grease DOAZ-19584-AA or SPECIAL SERVICE TOOL(S) REQUIRED
ESB-M 1C93-A to all the lobes. Description Tool Number
2. Assemble key, camshaft sprocket spacer and Camshaft Bearing Set T65L·6250·A
camshaft thrust plate to camshaft. Align the gear Fuel Line Removal Tool T93T-9550-AH
keyway with the key and install the camshaft
gear on the camshaft using Camshaft Gear Camshaft bearings are available prefinished to size for
Replacing Adapter T65L-6306-A. standard and 0.381 mm (0.0 15-inch) undersize journal
diameters.
ALL RIGHTS RESERVED
03-01 A-53 Engine, 4.9L Six-Cylinder 03-01 A-53
Removal 3. Remove the camshaft rear bearing cover. Refer

1. Remove the engine as outlined in this section and to Section 03-00. Remove the camshaft bearings
install on a work stand. with Camshaft Bearing Set T65L-6250-A.
2. Remove the connecting rod caps, flywheel
(6375) and crankshaft (6303). Push the pistons
to the top of the cylinders.
Camshaft Bearings, Removal/Installation
Part Part
1 - Pulling Screw 5 - Backup Nut
(Part of T65L-6250-A) (Part of T65L-6250-A)
2 - Pulling Plate 6 6262 Camshaft Center Bearing
(Part of T65L-6250..A) 7 - Puller Screw Extension
3 - Expanding Mandrel (Part of T65L-6250-A)
(Part of T65L-6250..A) 8 - Front Spacer
4 - Expanding Collet (Part of T65L-6250-A)
(Part of T65L-6250..A)
(Continued)
4. Select the proper size expanding collet and Installation

backup nut and assemble on the expanding 1. CAUTION: Failure to use the correct
mandrel. With the expanding collet collapsed, expanding collet can cause severe bearing
install the collet assembly in the camshaft damage.
bearings and tighten the backup nut on the
expanding mandrel until the collet fits the Position the new camshafts at the bearing bores,
camshaft bearings. and press them in place with Camshaft Bearing
Set T65L-625Q-A. Be sure to center the pulling
5. Assemble the puller screw and extension, if plate and puller screw to avoid damage to the
necessary, as shown and install on the expanding camshaft bearings.
mandrel. Wrap a cloth around the threads of the
puller screw to protect the front bearing or 2. Align the oil holes in the camshafts with the oil
journal. Tighten the pulling nut against the thrust holes in the cylinder block before pressing
bearing and pulling plate to remove the camshaft camshaft bearings into place. Be sure the front
bearings. Be sure to hold a wrench on the end of camshaft is installed 0.51-0.89mm
the puller screw to prevent it from turning. (0.020-0.035 Inches) below the front face of
the cylinder block.
6. To remove the camshafts (6250), install the puller
screw from the rear of the cylinder block (6010). 3. Install the camshaft rear bearing cover. Refer to
Section 03-00.
4. Install the camshaft, crankshaft, flywheel and
related parts. Do not check connecting rod and
main bearing clearances as a part of camshaft
bearing replacement.
1995 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain,DAVE GRAHAM

Drivetrain July 1994INC.
- 2014
ALL RIGHTS RESERVED
I 5. Install the engine in the vehicle.
Exhaust Manifolds
this section.
Removal
1. Remove the upper intake manifold (9424) and
throttle body (9E926).
tube (9D477) from the exhaust manifolds (9430).
3. Remove two clips and intake manifold shield 5
(9471).
4. Using 3/ 8-inch flex handle, rotate drive belt
©
tensioner (68209) and remove drive belt (8620).
5. Disconnect generator wiring.
6. Remove two screws and generator
(GEN)(10300). .
VIEWZ A24048-A
7. Disconnect air pump hoses.
8. Remove three screws and secondary air injection
pump pulley (98447). Part
9. Remove two screws and secondary air injection Item Number Description
pump (AIR pump)(9A486). 1 10300 Generator
10. Remove nut, three screws, and generator 2 8509 Water Pump Pulley
mounting bracket (10153). 3 380288-S2 Screw, 5/ 16-24 x 0.85
4 390785-S36 Screw, 3/8-16 x 1.25
5 391319-S2 Bolt, 7/ 16-14 x 5.5
6 3191314-S2 Bolt, 3/8-16 x 5.25
7 56561-S2 Bolt, 7/16-14 x 1.25
8 N802493-S2 Screw, M6-1.0 x 16
9 9B447 Secondary Air Injection
Pump Pulley
10 9A486 Secondary Air Injection
Pump
11 56540-S36 Bolt, 3/ 8-1~ x 1.0
12 56545-S2 Bolt, 3/8-16 x 2.25
13 382802-S2 Nut,3/8-16
(17-23 Lb-Ft)
(41-54 Lb-Ft)
(54-71 Lb-Ft)
(12-15 Lb-Ft)
(41-54 Lb-Ft) Refer to
procedure in text.
11. Remove the bolts attaching the front exhaust

manifold and rear exhaust manifold to the cylinder
head. Lift the manifolds from the engine. Remove
and discard the gaskets.

ALL RIGHTS RESERVED
03-01A-55 Engine, 4.9L Six-Cylinder 03-01 A-55
Installation 4. Make sure dowel pin is in place.

1. Clean the mating surfaces of the cylinder head, 5. Install rear exhaust manifold with bolts in holes 16
front exhaust manifold, rear exhaust manifold, and 15. Tighten bolts to 30-43 N·m (22-32Ib-ft).
lower intake manifold, and upper intake manifold. 6. Install front exhaust manifold and lifting eye with
2. NOTE: The EGR valve to exhaust manifold tube is stud in hole 13 and bolt i,n hole 14. Snug stud and
only on the rear exhaust manifold. tighten bolt to 30-43 N·m (22-32 Ib-ft).
If the rear manifold is to be replaced, remove the 7. Install intake manifold gasket (9439) over dowel
tube fittings from the discarded manifold as pin and line up port openings in the cylinder head
required. (6049) and intake manifold gasket.
3. On SFI engines, if either exhaust manifold is to be 8. Install the lower intake manifold onto dowel pin,
replaced, remove heated oxygen sensor then install remaining bolts.
(H02S)(9F472) from old manifold and install in
new one.
HEATED
OXYGEN
SENSOR
9F472
REAR EXHAUST
MANIFOLD
9431
FRONT EXHAUST
MANIFOLD
9430
HEATED OXYGEN SENSORS,
SFI EQUIPPED ENGINES
A24050-A

ALL RIGHTS RESERVED
03-01 A-56 E~gine, 4.9L Six-Cylinder 03-01 A-56
FRONT OF ENGINE
~
5 4
SECTION 8 VIEW A
A24051-A
Part Part
1 390754 Screw, 3/8-18 x 1.25 9 390530 Bolt, 3/8-16 x 1.31
2 9424 Lower Intake Manifold 10 9431 Rear Exhaust Manifold
3 9439 Intake Manifold Gasket 11 9F485 EGR Valve Tube to Manifold
4 6049 Cylinder Head Connector
5 - Dowel Pin 5/ 16 x 1.00 12 - Hole For Heated Oxygen
(Part of 6049) Sensor, used on California
Certified Vehicles with E40D
6 9430 Front Exhaust Manifold Transmission Only
7 17A084 Lifting Eye
A - Refer to Text for Tightening
8 391402 Stud, 3/8-16 x 3.57 Instructions
(Continued)

ALL RIGHTS RESERVED
03·01A·57 Engine, 4.9L Six-Cylinder 03·01A·57
9. Tighten bolts to 30-43 N·m (22-32 Ib-ft) in Part

numberical sequence shown.
1 - EGR Tube (Part of 9E452)
2 9E452 EGRVacuumAmplifier
3 390657 Bolt
4 - Bracket (Part of 9E452)
5 9424 Intake Manifold
Manifold Tube
A - Tighten to 16-24 N~
(12-18 Lb-Ft)
13. Connect air pump hoses.

14. Install generator and tighten bottom screw to
72-97 N·m (54-71 Ib-ft). Tighten top screw to
55-74 N·m (41-54Ib-ft).
~ 15. Install heat shield and two clips.
FRONT OF ENGINE 16. Reconnect all vacuum lines.
A1 0704-1 A 17. Install the upper intake manifold and throttle body
10. Install generator mounting bracket and three bolts as outlined in this section.
finger tight. Install nut finger tight.
a. Tighten bottom rear bolt to 55-74 N·m (41-54
Ib-ft).
b. Tighten center bolts to 55-74 N·m (4 1-54
Ib-ft).
c. Tighten nut to 55-74 N·m (41-54 Ib-ft).
d. Tighten bottom front bolt to 55-74 N·m (41-54
Ib-ft).
11. Install secondary air injection pump and tighten
bolts to 55-74 N·m (41-54 Ib-ft).
Oil Pan
12. Install secondary air injection pump pulley and
tighten screws to 16-21 N·m (12-15Ib-ft). Removal
assuming the engine (6007) has been removed
from the vehicle as outlined in this section. For
removal and installation of these components
with the engine installed in the vehicle, refer to
In-Vehicle Service in this section.
If not already done, remove oil pan drain plug
(6730) and drain oil from oil pan.
2. Remove the oil pan attaching bolts and remove oil
pan (6675).
3. Remove oil pan gasket (6710).
Installation
1. Clean cylinder block and oil pan flanges.
2. Apply WSG-M4G323-A3 sealer to parting lines
between rear main bearing cap and cylinder block
(6010), and between engine front cover (6019)
and cylinder block.
3. Position oil pan gasket on cylinder block flange.
Make sure oil pan gasket is positioned in rear
main bearing cap groove and tucked into
•
FRONT OF ENGINE
A24046-A
4.
cap-to-block slot.
Position oil pan on cylinder block flange.

ALL RIGHTS RESERVED
03-01 A-58 Engine, 4.9L Six-Cylinder 03-01A-58
5. Install four bolts in positions A as shown and Oil Pump

hand-tighten".
Removal
6. Install the rest of the bolts and tighten to 20-23
N·m (15-17 Ib-ft) except for bolt in position C. 1. Remove the oil pan (6675) following the
Tighten bolt in position C to 21-27 N·m (15-20 procedures under Oil Pan, Removal.
Ib-ft). 2. Remove the oil pump attaching bolts and oil pump
screen cover and tube retaining nut. Then,
remove the oil pump (6600).
Installation
(6A618) until oil emerges from the outlet opening.
2. Install the oil pump on the cylinder block (6010).
Tighten the attaching bolts and nuts to
specifications.
3. Install the oil pan following the procedures in this
section.
FRONT OF ENGINE
@1 ...
FRONT OF
ENGINE
~
A5Q92·H
Part
Reinforcement (RH)
2 390674 Screw
3 390674 Screw
4 390674 Screw
5 390674 Screw Part
6 390674 Screw Item Number Description
7 390674 Screw 1 391378 Screw, 5/ 16-18 x 1.13
8 6A674 Oil Pan Flange 2 33711 Nut
Reinforcement (LH) Oil Pump Screen Cover and
3 6622
9 390674 Screw Tube
10 6701 Crankshaft Rear Oil Seal 4 391378 Screw, 5/ 16-18 x 1.13
11 6710 Oil Pan Gasket 5 6626 Oil Pump Inlet Tube Gasket
12 6675 Oil Pan Assembly 6 - Dowel (Part of 6600)
A - Install First and 7 - Number 5 Main Bearing Cap
Hand-Tighten Stud (Part of 6010)
B - Install After Bolts A and 8 6600 Oil Pump
Tighten ALL to 20-23 N·m
(15-17 Lb-Ft)
(13-18 Lb-Ft)
C - Tighten to 21-27 N·m B - Tighten 30-43 N·m
(15-20 Lb-Ft) (22-32 Lb-Ft)

ALL RIGHTS RESERVED
Crankshaft The crankshaft (6303) and related parts are shown in

the illustration.
Crankshaft Seal Installer / Cover Aligner T88T-6701-A
Crankshaft, Disassembled View
A10367-C
Part Part
1 6378 Crankshaft Pulley Retaining 12 391547-S Bolt 7/16-14 x 3.36
Washer 13 6A338 Lower Main Bearing
2 6700 Crankshaft Front Seal 14 6A339 Lower Thrust Main Bearing
3 6306 Crankshaft Gear 15 - Main Bearing Caps
4 379153-S Key (Part of 6010)
5 6333 Upper Main Bearing 16 6303 Crankshaft
6 6337 Upper Thrust Main Bearing 17 6312 Crankshaft Pulley
7 6701 Crankshaft Rear Oil Seal 18 376706-S Bolt 5/8-18x 1.75
8 7120 Pilot Bearing A - Tighten to 102-115 N·m
9 391286-S Bolt 7/16-20 (75-85 Lb-Ft)
10 6384 Flywheel Ring Gear B - Tighten to 82-94 N·m
(60-69 Lb-Ft)
11 6375 Flywheel
(Continued)
Removal 3. Remove the crankshaft pulley attaching bolt and

1. Refer to Engine Removal and Installation in this lockwasher. Remove the crankshaft pulley
section. Install the engine (6007) on a work (6312).
stand. Remove the spark plugs (12405) to allow 4. Remove the engine front cover (6019) and
easy rotation of the crankshaft. Drain the gasket.
crankcase. 5. Remove the flywheel (6375) and engine rear
2. Remove the oil level dipstick (6750). plate (7007).

ALL RIGHTS RESERVED
6. Rotate the engine on the work stand so that the 12. Refer to Section 03-00 for the cleaning and
bottom of the engine is up. Remove the oil pan, inspection procedures. Be sure the oil seal
gaskets and seals. Remove the oil pump (6600) surfaces on the crankshaft and crankshaft
and oil pump screen cover and tube (6622). sprocket (6306) are properly cleaned.
Discard the oil pump inlet tube gasket (6626). 13. Remove the main bearing inserts from the
7. NOTE: Make sure all bearing caps (main and cylinder block and bearing caps.
connecting rod) are marked so that they can be 14. Remove the bearing inserts from the connecting
installed in their original locations. rod caps and connecting rods (6200).
Turn the crankshaft until the connecting rod cap 15. Clean the crankshaft rear oil seal recess in the
being removed is at the bottom of the stroke. cylinder block and rear main bearing cap.
Remove the connecting rod cap and bearings.
Push the connecting rod and piston assembly up Installation
in the cylinder. Do not rotate the crankshaft 1. If the crankshaft main bearing journals have been
completely around; the rod bolts may refinished to a definite undersize, install the
damage the crankpin journals. Repeat this correct undersize bearings. Be sure the bearing
procedure and remove all connecting rod caps. inserts and bearing bores are clean. Foreign
8. Remove the pilot bearing as described in material under the inserts will distort the bearing
Flywheel, Removal and Installation in this section, and cause a failure.
if necessary. 2. Place the upper main bearing inserts in position in
9. Align the timing marks. Remove the crankshaft the bore with the tang fitting in the slot provided.
gear as outlined. Be sure the oil holes in the bearing inserts are
aligned with the oil holes in the cylinder block.
3. Install the lower main bearing inserts in the
bearing caps with the tang fitted in the slot.
4. Carefully lower the crankshaft into place. Be
TIMING
MARKS careful not to damage the bearing surfaces.
5. Check the clearance of each crankshaft main
bearing (6333). Refer to Section 03-00. Seal the
rear main bearing-to-block mating surfaces as
directed in Crankshaft Main Bearings, Installation.
6. Apply a light coat of heavy engine oil to the
journals and bearings. Install all the bearing caps,
except the thrust bearing cap (No.5 bearing). Be
sure that the main bearing caps are installed
in their original locations. Tighten the bearing
cap bolts to 82-94 N·m (60-69Ib-ft).
10. Remove the main bearing caps and bearings and
crankshaft rear oil seal (6701). 7. Install the thrust bearing cap with the bolts
finger-tight.
11. NOTE: Handle the crankshaft with care to avoid
possible fracture or damage to the finished 8. Pry the crankshaft forward against the thrust
surfaces. surface of the upper half of the crankshaft thrust
main bearing (6337).
Carefully lift the crankshaft out of the cylinder
block (6010) so that the thrust bearing surfaces
are not damaged.

ALL RIGHTS RESERVED
Thrust Bearing, Installation
A10384-B
9. Hold the crankshaft forward and pry the thrust 17. Install the connecting rod cap and tighten the nuts
bearing cap to the rear. This will align the thrust to 55-61 N·m (40-45 Ib-ft).
surfaces of both halves of the crankshaft thrust 18. Check the connecting rod side clearance using a
main bearing. feeler gauge on each crankshaft journal after the
10. Retain the forward pressure on the crankshaft. piston and connecting rod assemblies have been
Tighten the cap bolts to 82-94 N·m (60-69 Ib-ft). installed. Refer to Specifications in this section.
11. Check the crankshaft end play. Refer to Section
03-00.
12. If the end play exceeds the specifications,
replace the crankshaft thrust main bearing. If the
end play is less than the minimum limit, inspect the
thrust bearing faces for scratches, burrs, nicks or
foreign matter. If the thrust faces are not
damaged or dirty, they probably need re-aligning.
Install the crankshaft thrust main bearing and
align the faces following the recommended
procedure (Steps 10 through 13 above). Then,
check the end play.
13. Coat a new crankshaft rear oil seal with oil and
install using Rear Oil Seal Replacer
T89P-670 1-AH. Refer to Crankshaft Rear Oil
Seal in this section. Inspect the seal to be sure it
was not damaged during installation.
14. Install the bearing inserts in the connecting rods
and caps. Check the clearance of each bearing
following the procedure under Connecting Rod
19. Clean the oil pan (6675), oil pump and oil pump
Bearing Replacement.
screen cover and tube.
15. If the bearing clearances are to specifications,
apply a light coat of engine oil to the journals and 20. Install the oil pump screen cover and tube with
connecting rod bearings (6211). new gasket on the oil pump. Prime the oil pump by
filling the inlet opening with oil and rotate the oil
16. Turn the crankshaft throw to the bottom of its pump intermediate shaft (6A618) until oil
stroke and pull the piston all the way down until emerges from the outlet opening. Install the oil
the connecting rod bearing seats on the pump. Tighten the attaching bolts to 14-20 N·m
crankshaft journal. (10-15Ib-ft).

ALL RIGHTS RESERVED
03·01A·62 Engine, 4.9L Six-Cylinder 03-01A-62
21. Install the pilot bearing on the crankshaft for a

manual transmission (7003). Refer to Mainshaft REAR MAIN
Bearing Roller, Removal and Installation in this BEARING CAP
section.
On a flywheel for a manual transmission, locate
the clutch disc (7550) following the procedure in
this manual. Install the clutch pressure plate
(7563). Tighten the attaching bolts to 102-115
N·m (75-85 Ib-ft).
22. Turn the engine on the work stand so that the rear
of the engine is up. Position the engine rear plate
on the cylinder block. Position the flywheel on the
crankshaft. Coat the threads of the attaching
bolts with Pipe Sealant with Teflon@
D8AZ-19554-A or equivalent meeting Ford
specification WSK-M2G350-A2 oil-resistant
OIL SEAL
sealer and install the bolts. Tighten the bolts to A10353-e
102-115 N·m (75-85 Ib-ft).
29. Install the oil level dipstick.
23. Turn the engine on the work stand so that the
front end is up. 30. Remove the engine from the work stand and
install it in the vehicle. Refer to Engine Removal
24. Install the crankshaft sprocket following the
and Installation in this section. Fill the crankcase.
procedure under Timing Sprocket, Installation.
Fill and bleed the cooling system. Refer to
25. Install a new oil-coated crankshaft front seal Section 03-03.
(6700) in the engine front cover using Crankshaft
31. Start the engine and check all gaskets and hose
Seal Installer / Cover Aligner T88T-670 1-A. Install
connections for leaks.
the engine front cover and crankshaft pulley by
following the procedure outlined under Engine 32. Check the ignition timing as outlined in Section
Front Cover, Installation. 03-07A.
I
CRANKSHAFT SEAL
INSTALLER/COVER ALIGNER Crankshaft Main Bearings
T88T-6701-A
to Description Tool Number
Main Bearing Insert Tool TOOL-6331-E
Do not file or lap bearing caps or use shims to

obtain the proper bearing clearance.
Bearings are available for service in standard sizes or
.010 and .020 inch undersize. Refer to the Parts
Catalog for the available sizes. Undersize bearings are
available for use on journals that have been refinished.
If the rear main bearing is to be replaced, it will be
A10352-e necessary to remove the engine, install it on a work
stand, replace the rear main bearing and replace the
26. Apply Perfect Seal Sealing Compound crankshaft rear oil seal (6701).
B5A-19554-A or equivalent meeting Ford .
specification ESE~M4G 115-A oil-resistant sealer Removal
in the cavities between the rear bearing cap and 1. NOTE: If crankshaft main bearings (6333) need
cylinder block. to be replaced, crankshaft (6303) should be
27. Install a new crankshaft rear oil seal in the rear removed to check crankshaft journals for
main bearing cap. . damage. Refer to Section 03-00 for inspection
procedures.
28. Install new gasket on the crankshaft with 'Gasket
and Trim Adhesive 07AZ-19B508-AA or Drain the crankcase. Remove the oil pan (6675),
equivalent meeting Ford specifications oil pump (6600) and oil pump screen cover and
ESE-M2G52-A oil-resistant sealer. Install the oil tube (6622) following the procedure in this
pan. section.

ALL RIGHTS RESERVED
2. NOTE: Loosen all main bearing caps until just Installation

finger-tight. This will loosen the crankshaft and The upper and lower bearing halves are not
ease installation of new bearings. interchangeable. The upper half is drilled and
Replace one crankshaft main bearing at a grooved to provide entry of oil.
time, leaving the other bearings securely 1. Be sure bearings and surfaces are clean. Foreign
fastened. Remove the main bearing cap to which material under the inserts will distort the bearings
new bearings are to be installed. and cause premature wear.
3. Insert Main Bearing Insert Tool TOOL-6331-E in 2. To install the upper main bearing, place the plain
the oil hole in the crankshaft journal. end of the bearing over the shaft on the locking
tang side of the cylinder block and partially install
the bearing so that Main Bearing Insert Tool
TOOL-6331-E can be inserted in the oil hole in the
crankshaft journal. With tool positioned in the oil
hole, rotate the crankshaft slowly in the opposite
direction of engine rotation until the bearing is
seated. Remove the tool.
3. Check bearing clearance as outlined in Section
03-00.
4. After the bearing clearance has been found within
specifications, apply a light coat of engine oil to
the journal and bearings. Then, install the bearing
cap.
5. lighten the cap bolts to 82-94 N·m (60-691b-ft).
6. Repeat the procedure for the remaining bearings
that require replacement.
CRANKSHAFT 7. If the thrust bearing cap (No.5 main bearing) has
JOURNAL A10363-B been removed, install it as follows:
4. Rotate the crankshaft in the direction of engine Install the thrust bearing cap with the bolts
rotation to force the bearing out of the cylinder finger-tight. Pry the crankshaft forward against
block (6010). the thrust surface of the upper half of the bearing.
5. Clean the crankshaft journal. When replacing Hold the crankshaft forward and pry the thrust
standard bearings with new bearings, first try to bearing cap to the rear. This will align the thrust
obtain the proper clearance with standard surfaces of both halves of the bearing. Retain the
bearings or a combination of a standard bearing forward pressure on the crankshaft. Tighten the
and a .010- or .020-inch undersize bearing. cap bolts to 82-94 N·m (60-69Ib-ft).
A10364-8

ALL RIGHTS RESERVED
03-01A-64 Engine, 4~9L Six-Cylinder 03-01A-64
8. If the rear main bearing is replaced (on a work 2. Remove the oil pan (6675) following the
stand), clean the mating surfaces of the bearing procedure in this section. Remove the oil pump
cap and the cylinder block with Ford Metal screen cover and tube (6622) and the oil pump
Surface Cleaner F4AZ-19A536-RA or equivalent (6600).
solvent meeting Ford specifications 3. CAUTION: Never cut Into the ring travel area
WSE-M5B392-A. in excess of 0.74mm (1 /32 Inch) when
9. NOTE: When applying RTV sealant, always use removing ridges.
the bead size specified and join the components Rotate the crankshaft (6303) until the piston to
within 15 minutes of application. After this amount be removed is at the bottom of the stroke and
of time the sealant begins to "set-up" and its place a cloth on the piston dome to collect the
sealing effectiveness may be reduced. cuttings. Remove any ridge and / or deposits from
Apply a 1.6mm (1 / 16-inch) bead of RTV sealer, the upper end of the cylinder bore with Cylinder
Silicone Rubber D6AZ-19562-BA or equivalent Ridge Reamer T64L-60 11-EA. Follow the
meeting Ford specifications ESE-M4G 195-A in instructions furnished by the tool manufacturer.
each corner of the rear main bearing cap saddle 4. Make sure all the connecting rod caps are
the full length of the saddle. Be sure the main marked so that they can be installed in their
bearing is fitted and the cap bolts tightened original positions. Remove the connecting rod
to 82-94 N·m (60-70 Ib-ft) before installing cap.
the new crankshaft rear oil seal.
5. Push the connecting rod and piston assembly out
10. Clean the oil pump screen cover and tube. Prime the top of the cylinder with the handle end of a
the oil pump by filling the inlet opening with oil and hammer. Avoid damage to the crankshaft journal
rotate the oil pump intermediate shaft (6A618) or the cylinder wall when removing the piston and
until the oil emerges from the outlet opening. rod.
11. Install the oil pump and oil pan following the
procedure in this section. Installation
12. Fill crankcase with oil specified in Section 00-03 1. Clean the oil pump screen cover and tube and the
and cooling system as outlined in Section 03-03. oil pan and cylinder block (6010) gasket
Start the engine (6007) and check for oil surfaces.
pressure. Operate the engine at fast idle and 2. Oil the piston rings, pistons and cylinder walls
check for oil and coolant leaks. with light engine oil.
3. Make sure pistons are installed in the same
cylinders from which they were removed or
to which they were fitted. The connecting rods
Pistons and Connecting Rods (6200) and bearing caps are numbered from 1 to
6 beginning at the front of the engine (6007). The
SPECIAL SERVICE TOOL(S) REQUIRED number on the connecting rod and bearing cap
must be on the same side of rod when installing in
Description Tool Number the cylinder bore. If a connecting rod is ever
Cylinder Ridge Reamer T64L-6011-EA transferred from one cylinder block to another or
from one cylinder to another, new connecting rod
Removal bearings (6211) should be fitted and the
1. Refer to Cylinder Head, Removal in this section connecting rod should be renumbered to
and remove the cylinder head (6049) and related correspond with the new cylinder number.
parts.
ALL RIGHTS RESERVED
4. Make sure the ring gaps (oil ring spacer A, oil ring 7. Rotate the crankshaft to the bottom of its stroke.
segment B, and compression ring C) are properly Then, push the piston all the way down until the
spaced around the circumference of the piston. connecting rod bearing seats on the crankshaft
Oil the rings, then install Piston Ring Compressor journal. Install the connecting rod cap. Tighten the
081 L-6002-C or equivalent on the piston. Make nuts to 55-61 N·m (41-451b-ft).
sure that the indentation in the dome of piston is 8. After the piston and connecting rod assemblies
toward the front. have been installed, check the connecting rod
• Push the piston into its bore with the handle side clearance using a feeler gauge on each
end of a hammer until it is slightly below the top crankshaft journal.
of the cylinder. Be sure to guide the connecting
rods to avoid damaging the crankshaft
journals.

C (6A618) until oil emerges. from the outlet opening.
PISTON
Install the oil pump oil pump and the oil pump
6108 screen cover and tube. Install the oil pan and
A2811-C related parts as outlined in this section.
10. Refer to Cylinder Head, Installation, and install the
cylinder head and related parts. Adjust the valve
clearance as outlined in this section.
11. Install engine. Refer to Engine Removal and
Installation in this section.
Connecting Rod Bearings

Removal
1. Remove the oil pan (6675) and oil pump (6600)
following the procedure in this section.
2. NOTE: If connecting rod bearings (6211) are to
be reused, identify them according to location so
that they can be installed in their original
positions.
Rotate the crankshaft (6303) until the connecting
rod (6200) to which new bearings are to be fitted
5. Check the clearance of each connecting rod is at the bottom of the stroke. Remove the
following the procedure under Fitting Main or connecting rod cap. Remove the bearing inserts
Connecting Rod Bearing in Section 03-00. from the connecting rod and cap.
6. After the connecting rod bearings have been 3. Make sure the bearing inserts and the bearing
fitted, apply a light coat of engine oil to the bore in the connecting rod and cap are clean.
journals and bearings. Foreign material under the inserts will distort the
bearing and cause premature wear.

ALL RIGHTS RESERVED
4. Clean the crankshaft journal. When replacing A needle roller bearing and adapter assembly is used
standard size bearings with new bearings, first as a pilot bearing on F-150-25Q-350 vehicles. It is
try to obtain the proper clearance with standard inserted directly into the crankshaft. The bearing and
size bearings. Refer to Section 03-00 for the adapter assembly cannot be serviced separately. The
cleaning and inspection procedures. pilot bearings can only be installed with the seal end of
the bearing facing the transmission (7003). The pilot
Installation bearings are pregreased and do not require additional
1. Install the bearing inserts in the connecting rod lubrication. A new pilot bearing must be installed
and cap with the tangs fitted in the slots. whenever a transmission pilot bearing is removed. For
2. Pull the connecting rod down firmly on the additional information refer to Section 08-01.
crankshaft journal.
Check bearing clearance. Refer to Section MAINSHAFT
BEARING
03-00. ROLLER-7120
3. After the bearing clearance has been checked
and found OK or concern corrected, clean and
apply a light coat of engine oil to the journal and RECESS FOR
bearings. Install the connecting rod cap and REMOVAL
tighten the nuts to 55-61 N·m (4 1-45 Ib-ft). TOOL
4. Repeat the procedure for the remaining

connecting rods that require new connecting rod SEAL
bearings.
5. Install the oil pan and oil pump following the
procedures under Oil Pan, Installation in this
section. C2981·C
Removal
1. Remove the transmission as outlined in the
Flywheel appropriate section in Group 07. Remove the
clutch pressure plate (7563), and clutch disc
Removal (7550). Refer to Section 08-01.
1. Remove the transmission (7003) following the 2. Using Puller T58L-101-B, remove the pilot
procedure in the appropriate transmission section bearing.
in Group 07.
2. On a manual transmission, remove the clutch
pressure plate (7563) and cover assembly and
clutch disc (7550) following the procedure in
Section 08-01.
3. NOTE: To check flywheel face runout or replace
the flywheel ring gear (6384), refer to Section
03-00.
Remove the flywheel attaching bolts and remove
the flywheel (6375).
order. Coat the threads of the flywheel attaching
bolts with oil-resistant sealer and install the bolts.
Tighten in an opposing pattern to 102-115 N·m
(75-85Ib-ft).
Mainshaft Bearing Roller

Description Tool Number A10380-E
Puller T58L-101-B
Pilot Bearing Replacer T74P-7137-A

ALL RIGHTS RESERVED
Installation 4. Clean the oil seal recess in the cylinder block and
1. Using Pilot Bearing Replacer T74P-7137-A, main bearing cap. Inspect and clean the oil
install the pilot bearing with the seal facing the seal contact surface on the crankshaft.
transmission so that the adapter is not
misaligned.
A10381·B
Installation
2. NOTE: Care must be taken not to damage the 1. Coat the oil seal-to-cylinder block surface of the
pilot bearing while the transmission input shaft is crankshaft rear oil seal with oil XQ-5W3Q-aSp or
being inserted into the pilot bearing during -DSP or equivalent meeting Ford specifications
transmission installation. ESE-M2C153-E. Coat the seal contact surface of
Install the clutch pressure plate, clutch disc as the crankshaft rear oil seal and crankshaft with
outlined in Section 08-01. heavy SF engine oil. Place crankshaft rear oil
seal on Rear Oil Seal Installer T89T-7601-AH
and, using hammer, tap into place until tool
contacts face of cylinder block or bearing cap.
Crankshaft Rear Oil Seal 2. Install flywheel (6375). Tighten flywheel attaching
Removal bolts as follows:
1. NOTE: The steps in this procedure are written a. First stage - 12-15 N·m (9-11Ib-ft).
assuming the engine (6007) has been removed b. Second stage - 68-74 N·m (50-55 Ib-ft).
from the vehicle as outlined in this section. For 3. If equipped, install clutch as outlined in Section
removal and installation of these components 08-01.
with the engine installed in the vehicle, refer to
In-Vehicle Service in this section.
If equipped with manual transmission (7003),
remove clutch as outlined in Section 08-01.
2. Remove the flywheel attaching bolts.
3. Use an awl to punch two holes in the crankshaft
crankshaft rear oil seal (6701). Punch the holes
on opposite sides of the crankshaft (6303) and
just above the bearing cap-to-eylinder block split
line. Install a sheet metal screw in each hole. Use
two large screwdrivers or small pry bars and pry
against both screws at the same time to remove
the crankshaft rear oil seal. It may be necessary
to place small blocks of wood against the cylinder
block (6010) to provide a fulcrum point for the pry
bars. Use caution throughout this procedure
to avoid scratching or otherwise damaging
the crankshaft 011 seal surface.

ALL RIGHTS RESERVED
NOTE: Perform other needed maintenance and 2. Refer to core plug service procedures in Section
reinstall engine as outlined in this section. 03-00 to remove the camshaft rear bearing
cover.
order. Coat the flywheel bolts with pipe sealant
Teflon@ D8AZ-19554-A or equivalent meeting
Ford specification WSK-M4G350-A2 and tighten
in an opposing pattern to 102-115 N·m (75-85
Ib-ft).
Oil Filter
Removal
assuming the engine (6007) has been removed
A23871-A from the vehicle as outlined in this section. For
removal and installation of these components
Part with the engine installed in the vehicle, refer to
Item Number Description In-Vehicle Service in this section.
1 - Crankshaft (Part of 6303) Place a drip pan under the oil filter. Unscrew the
2 - Crankshaft Seal Bore oil filter from the cylinder block (6010) using Oil
(Part of 6010) Filter Wrench D79L-6731-A, -B or equivalent.
3 6010 Cylinder Block Installation
4 - Plug Bore (Part of 6010)
1. Coat the gasket on the oil filter with oil. Place the
5 6266 Camshaft Rear Bearing oil filter in position on the cylinder block.
Cover
Hand-tighten the oil filter until the gasket contacts
6 T78T-670 1-AH Rear Oil Seal Replacer the adapter face, then advance it one-half turn.
8 - Metallic Side of Seal NOTE: Perform other needed maintenance and
(Part of 6266) reinstall engine as outlined in this section.
Camshaft Rear Bearing Bore Plug Oil Level Indicator Tube

NOTE: The steps in this procedure are written Removal and Installation
assuming the engine (6007) has been removed from 1. Remove oil level dipstick (6750).
installation of these components with the engine 2. Remove nut securing oil level indicator tube
installed in the vehicle, refer to In-Vehicle Service in bracket to valve pushrod cover retainer.
this section. 3. Unscrew oil lever indicator tube retaining nut and
remove oil level indicator tube (6754) from engine
Removal and Installation (6007).
1. Remove the flywheel attaching bolts. Remove the
flywheel (6375) anGt the engine rear plate (7007).

ALL RIGHTS RESERVED
4. Reverse removal steps to install. Tighten oil level 4. Connect oil pressure sensor.
indicator tube retaining nut to 20-24 N·m (15-17 NOTE: Perform other needed maintenance and
Ib-ft). Tighten oil level indicator tube to valve reinstall engine as outlined in this section.
pushrod cover retainer nut to 4-5 N·m (35-44
Ib-in).
.-
FRONT
OF
ENGINE
ENGINE
6010
•
FRONT OF ENGINE
A23875-A
Part
Item Number Description A23872-A
1 6750 Oil Level Dipstick
2 370786-58 Nut, Stamped 15/16
3 6754 Oil Level Indicator Tube DISASSEMBLY AND ASSEMBLY
Retaining Nut (Part of 6754)
Subassemblies
Bracket (Part of 6754) Cylinder Head
6 6C517 Retainer Assembly
7 6519 Valve Pushrod Cover SPECIAL SERVICE TOOL(S) REQUIRED
Valve Spring Compressor T70P-6049-A
Sensors Valve Stem Seal Replacer T87L-6571-BH
Oil Pressure Switch Disassembly

Removal and Installation 1. Remove the water outlet connection and water
1. NOTE: The steps in this procedure are written thermostat (8575). Discard the oil cooler return
assuming the engine (6007) has been removed tube gasket (6N789).
from the vehicle as outlined in this section. For 2. Remove the lower intake manifold (9424) and
removal and installation of these components exhaust manifolds (9430) from the cylinder head
with the engine installed in the vehicle, refer to (6049). Discard the gaskets.
In-Vehicle Service in this section. 3. Remove the spark plugs (12405).
Disconnect oil pressure switch lead. 4. Remove the deposits from the combustion
2. Using suitable oil pressure sender socket, chambers and valve heads with a scraper and a
remove oil pressure sensor (9278). wire brush before removing the valves. Be careful
3. Start replacement oil pressure sensor by hand. not to scratch the cylinder head gasket surface.
Using suitable oil pressure sender socket, tighten
to 11-24 N·m (8-181b-ft).

ALL RIGHTS RESERVED
DISASSEMBLY AND ASSEMBLY (Continued)
5. Compress each valve spring (6513) using Valve

Spring Compressor T70P-6049-A, then remove Part
the valve spring retainer keys (6518) and release Item Number Description
the valve spring. 3 6513 Valve Spring
4 6571 Valve Stem Seal
5 6507 Intake Valve
6 6505 Exhaust Valve
7 6513 Valve Spring
8 6514 Valve Spring Retainer
Assembly
1. Lubricate the valve guides and valve stems with
engine oil. Apply Multi-Purpose Grease
specifications ESB-M 1C93-A to the tip of the
valve stems.
2. Install each intake valve (6507) in the valve guide
from which it was removed or to which it was
fitted.
3. Install new valve stem seals. Use a 5/ 8-inch deep
well socket and a light hammer or mallet to seat
the seal on the valve guide or use Valve Stem
Seal Replacer T87L-6571-BH. Place the valve
6. Remove the valve spring retainer (6514), valve spring in position over the valve and install the
spring, valve stem seal (6571) and valve. Discard valve spring retainer and sleeve, if so equipped.
the valve stem seal. Compress the valve spring and install the valve
tool and rocker arm seat bolt.
4. Install the valve spring over the intake valve.
Make sure the closed coli end Is placed
against the cylinder head.
5. Position valve spring retainer on the appropriate
valve spring. Make sure that a positive rotating
retainer is used on all of the exhaust valves
(6505).
6. Compress the spring. Install the valve spring
retainer keys. Tap the retainers of each intake
valve after assembly to seat the keys.
7. Measure the assembled height of the valve spring
from the surface of the cylinder head spring pad
to the underside of the spring retainer with
dividers.
8. NOTE: Refer to Specifications for proper valve
spring assembled height.
CAUTION: Do not install spacers unless
necessary. Use of spacers in excess of
recommendations will result In overstressing
the valve springs and overloading the
camshaft lobes which could lead to spring
breakage or worn camshaft lobes.
Check the dividers against a scale. If the
A10388-C assembled height is greater than the specified
limit, install the necessary 0.76mm (0.03Q-inch)
Part thick spacer(s) between the cylinder head spring
Item Number Description pad and the valve spring to bring the assembled
height to the recommended dimension.
1 6518 Valve Spring Retainer Keys
2 . 6514 Valve Spring Retainer
(Continued)
ALL RIGHTS RESERVED
9. Install valve cover. 10. Make sure dowel pin is in place.

11. Install rear exhaust manifold with bolts in holes 16
and 15. Tighten bolts to 30-43 N·m (22-32 Ib-ft).
12. Install front exhaust manifold and lifting eye with
stud in hole 13 and bolt in hole 14. Snug stud and
tighten bolt to 30-43 N·m (22-32 Ib-ft).
13. Install intake manifold gasket (9439) over dowel
pin and line up port openings in the cylinder head
and intake manifold gasket.
14. 'nstall the lower intake manifold onto dowel pin,
then install remaining bolts.
SURFACE OF
SPRING PAD A10087·1A
FRONT OF ENGINE
~
5 4
SECTION B VIEW A
A24051-A
Part Part
1 390754 Screw, 3/8-18 x 1.25 4 6049 Cylinder Head
2 9424 Lower Intake Manifold 5 - Dowel Pin 5/ 16 x 1.00
3 9439 Intake Manifold Gasket (Part of 6049)
ALL RIGHTS RESERVED
- -
Part Part
6 9430 Front Exhaust Manifold 12 - Hole For Heated Oxygen
7 17A084 Lifting Eye Sensor, used on California
8 391402 Stud, 3/8-16 x 3.57 Certified Vehicles with E40D
Transmission Only
9 390530 Bolt, 3/8-16 x 1.31
10 9431 Rear Exhaust Manifold
A - Refer to Text for Tightening
Instructions
11 9F485 EGR Valve Tube to Manifold
Connector
(Continued)
15. TIghten bolts to 30-43 N·m (22-32 Ib-ft) in Piston and Connecting Rod
numerical sequence shown.
Piston Pin Remover / Replacer T81 P-6135-A
Disassembly
1. Remove the connecting rod bearing (6211) from
the connecting rod and cap.
2. Mark the pistons and pins to make sure of
assembly with the same connecting rod (6200)
and installation in the same cylinder from which
they were removed.
3. Remove the piston rings. Using an arbor press
and Piston Pin Remover / Replacer 181P-6135-A,
.,
FRONT OF ENGINE
press the piston pin from the piston and
connecting rod.
Refer to Section 03-00 for cleaning, inspection
and repair procedures.
A10704-1A
16. Using a new thermostat housing gasket coated
with Perfect Seal Sealing Compound
B5A-19554-A or equivalent sealer meeting Ford
specification ESE-M4G 115-A water-resistant,
install the water thermostat and water outlet
connection. Refer to Section 03-03. TIghten the
attaching bolts to 17-24 N·m (12-18 Ib-ft).

ALL RIGHTS RESERVED
Piston Pin, Removal and Installation The piston pin bore of a connecting rod and the
diameter of the piston pin must be within specifications
at the·back of this section.
PERED PILOT
2 IN PISTON PIN FOR
PIN REMOVAL
INSERT THIS END
IN PISTON HOLE
FOR INSTALLATION
A10370-B
Part
1 - Lower Compression Ring
(Part of 6148)
REMOVAL INSTALLATION 2 - Oil Ring Assembly
A4871·F (Part of 6148)
3 - Piston (Part of 6108)
Part 4 6211 Connecting Rod Bearings
Item Number Description 5 - Connecting Rod Cap
(Part of 6200)
1 - Driver (Part of T68P-6135-A)
6 6212 Connecting Rod Nut
2 - Reversible Locator
(Part of T68P-6135-A)
3 - Adapter 8 6200 Connecting Rod
(Part of T68P-6135-A) 9 - Piston Pin (Part of 6108)
4 - Cap (Part of T68P-6135-A) 10 - Upper Compression Ring
5 - Pin Pusher (Part of 6148)
6 - Piston Pin (Part of 6108)
7 - Receiving Tube
Assembly
The piston, connecting rod and related parts are
shown in the illustration. Check the fit of a new piston
in the cylinder bore before assembling the piston and
piston pin to the connecting rod bearing. Refer to
Section 03-00.

ALL RIGHTS RESERVED
1. Apply a light coat of engine oil to all parts. 1. Grasp the lock ring with needlenose pliers to
Assemble the piston to the connecting rod release it from the groove. It may be necessary to
with the bearing tang side of the connecting depress the plunger to fully release the lock ring.
rod and the indentation notch in the piston 2. Remove the push rod cup, metering valve (disc),
positioned as shown. plunger and spring.
3. Invert the plunger assembly and remove the
check valve retainer by carefully prying up on it
with a screwdriver. Remove the check valve (disc
or ball check) and spring.
For cleaning and inspection procedures, refer to
Section 03-00.
t!f/!!J
FRONT
TYPICAL A10371·B
2. Start the piston pin in the piston and connecting

rod. Using an arbor press, press the piston pin
through the piston and connecting rod until the pin
is centered in the connecting rod. To install piston
pin use Piston Pin Remover / Replacer
T81P-6135-A.
A10369-C
3. Check the end gap of all piston rings with a feeler
gauge. It must be within specifications listed at
end of this section. Install the piston rings Part
following the instructions on the package. Item Number Description
4. Check the ring side clearance of the compression 1 - Push Rod Cap (Part of 6500)
rings with a feeler gauge inserted between the 2 - Metering Valve Disc
ring and its lower land. The gauge should slide (Part of 6500)
freely around the entire ring circumference 3 - Check Valve (Part of 6500)
without binding. Any wear that occurs will form a 4 - Plunger Spring (Part of 6500)
step at/the inner portion of the lower land. If the 5 - Body (Part of 6500)
lower lands have steps, the piston should be 6 - Check Valve Retainer
replaced. (Part of 6500)
5. Make sure the connecting rod bearings and the 7 - Check Valve Spring
(Part of 6500)
bearing bore in the connecting rod and cap are
clean. Foreign material under the inserts will 8 - Plunger (Part of 6500)
distort the bearing and cause a failure. Install the 9 - Lock Ring (Part of 6500)
bearing inserts in the connecting rod and cap with
the tangs fitting in the slots provided. Assembly
1. Place the plunger upside down on a clean work
bench.
2. Place the check valve (disc or ball check) in
Valve Tappet, Hydraulic position over the oil hole on the bottom of the
NOTE: Valve tappets (6500) should always be tested plunger. Set the check valve spring on top of the
after assembly. Refer to the test procedures in check valve (disc or ball check).
Section 03-00. 3. Position the check valve retainer over the check
Disassembly valve and spring. Push the retainer down into
place on the plunger.
Each valve tappet is a matched assembly. If the parts
of one valve tappet are mixed with those of another, 4. Place the plunger spring and then the plunger
improper valve operation may result. Disassemble and (open end up) into the tappet body.
assemble each valve tappet separately. Keep the 5. Position the metering valve (disc) in the plunger
valve tappet assemblies in proper sequence so that and then place the push rod cup in the plunger.
they can be installed in their original bores.
DAVE
Drivetrain INC.
- 2014
July 1994
ALL RIGHTS RESERVED
6. Depress the plunger and position the closed end 3. Remove the cylinder head to block dowels
of the lock ring in the groove of the tappet body. (6AOOa).
With the plunger still depressed, position the
open ends of the lock ring in the groove. Release' Assembly
the plunger and then depress it again to ft)lIy seat 1. Clean the gasket and seal surfaces of all
the lock ring. . serviceable parts and assemblies.
7. Use the hydraulic valve tappet leak-down tester 2. Position the new cylinder block (6010) in the
to fill the valve tappets with test fluid. Refer to work stand and transfer all serviceable parts
Section 03-00. removed from the cylinder block following engine
components removal and installation procedures.
3. Install the cylinder head to block dowels and
block drain plugs.
Cylinder Block Assembly 4. Check all assembly clearances and correct as
Disassembly necessary.
1. Mount the engine (6007) in a work stand.
2. Remove the cylinder head (6049) and intake and ADJUSTMENTS
exhaust mani,olds.
3. Remove all serviceable parts not furnished with
the new cylinder block assembly, including the Valve Clearance
cylinder block drain plugs and cylinder head to
block dowels (6AOOa). SPECIAL SERVICE TOOL(S) REQUIRED
Assembly Description Tool Number

Tappet Bleed Down Wrench T70P-6513-A
1. Clean the gasket and seal surfaces of all
serviceable parts and assemblies. A 1.52mm (0.060 inch) shorter push rod (6565) or a
2. Position the new cylinder block (6010) assembly 1.52mm (0.060 inch) longer push rod is available for
in a work stand and transfer all serviceable parts service to provide a means of compensating for
removed from the old cylinder block assembly. dimensional changes in the valve mechanism. Refer to
Follow removal and installation procedures in this the Ford Master Parts List for the appropriate color
section. code.
3. Install the cylinder head to block dowels and Valve stem-to-valve rocker arm clearance should be
block drain plugs. Install the cylinder head and within specifications with the valve tappet (6500).
manifolds as an assembly. Refer to Specifications. Repeated valve reconditioning
4. Check all assembly clearances and correct as operations (valve and / or valve seat refacing) will
necessary. Refer to Section 03-00. decrease the clearance to the point that if it is not
compensated for, the hydraulic valve tappet will
collapse and cease to function, and could prevent the
valve seat face from properly seating on the valve
seat. Valve will be held open.
Cylinder Block, Bare
The positive stop rocker arm bolt eliminates the
Before replacing a cylinder block, determine if it is necessity of adjusting the valve clearance. However,
repairable. If so, make the necessary repairs. Refer to to obtain the specified valve clearance, it is important
Section 03-00. that all valve components be in a serviceable condition
Disassembly and installed and tightened to specifications. Refer to
Specifications in this section.
1. Mount the engine in a work stand and completely
disassemble it, removing the cylinder head and To determine whether a shorter or a longer push rod is
intake and exhaust manifolds as an assembly. necessary, make the following check.
Follow removal and installation procedures in this 1. Install an auxiliary starter switch. Crank the
section. engine (6007) with the ignition switch in the
2. Ridge-ream the cylinder bores before removing OFF position.
the piston assemblies.
ALL RIGHTS RESERVED
ADJUSTMENTS (Continued)
2. Make two chalk marks on the crankshaft pulley 3. lighten the rocker arm bolts of the No. 1 intake
(6312). Space the marks approximately 120 and exhaust valves to specifications with No. 1
degrees apart so that, with the timing mark, the piston on TOe at the end of the compression
crankshaft pulley is divided into three equal parts stroke.
( 120 degrees is one-third of the distance around Then slowly supply pressure to bleed down the
the damper circumference). valve tappet until the plunger is completely
bottomed using Tappet Bleed Down Wrench
STEP 1 - SET NO.1 PISTON ON T.D.C. AT END OF COMPRESSION
STROKE ADJUST NO.1 INTAKE AND EXHAUST T70P-6513-A.
STEP 4 - CHECK NO.6 INTAKE AND EXHAUST Hold the valve tappets in this position and check
the available clearance between the rocker arms
(6564) and the valve stem tip with a feeler gauge.
• If the clearance is less than specifications,
/ install a shorter push rod.

• If the clearance is greater than specifications,
install a longer push rod.
STEP 2 - CHECK NO.5 STEP 3 - CHECK NO. 3

INTAKE AND EXHAUST INTAKE AND EXHAUST
STEP 6 - CHECK NO.2 STEP 6 - CHECK NO.4
INTAKE AND EXHAUST INTAKE AND EXHAUST
A1001I-1A A2232-G
4. Repeat this procedure for the remaining set of

valves, turning the crankshaft (6303) with an
auxiliary starter switch, one-third turn at a time, in
the direction of rotation. At the same time, adjust
the valves in the firing order sequence,
1-5-3-6-2-4.
SPECIFICATIONS
Refer to the following charts for engine specifications.

GENERAL SPECIFICATIONS
011 Pressure Engine Type
Hot @ 2000 rpm and Number of
Engine Bore and Stroke Firing Order kPa (PSI) Cylinders
4.9L (300 CID) 1-6 4.00x3.98 153624 275 (40-60) O.H.V.I-6
DAVE
1995 F-150. F-250. F-350. Bronco. F-Super Duty Powertrain. GRAHAM
Drivetrain INC.
- 2014
July 1994
ALL RIGHTS RESERVED
CYLINDER HEAD
Valve Guide Valve Seat
Bore Diameter Width·
Combustion Rocker Arm
Chamber Valve Seat Valve Gasket Fulcrum
Volume RunoutTIR Arrangement Surface Thread
Engine C.C. b Intake Exhaust Intake Exhaust Maximum Front to Rear FlatnessC Diameter Std.·
.006 in any
65.4- .3433- .3433- .060- .070- E-I-E-I-E-I-
4.9L (300) .002 6 inches 5/16-18
68.4 .3443 .3443 .080 .090 E-I-E-I-E-I
0.010 overall
a Valve seat angle - 45 0 •
b Compression pressure (PSI) of the lowest cylinder must be at least 75% of the highest to be within specification.
c Gasket surface finish - rms 60-150.
VALVE ROCKER ARM SHAFT, PUSH RODS AND TAPPETS

Collasped Tappet Gap
Valve Tappet or Lifter (Clearance)
Push Rod Hydraulic Lifter
Rocker Arm Runout Standard Clearance Leak-down
Engine Lift Ratio to 1 TIRMaxlmum Diameter to Bore· Rateb Allowable Desired
10 to 50 seconds
4.9L (300 CID) 1-6 1.61 .015 .8740-.8745 .0007-.0027 .100-.200 .125-.175
for 1/ 16 travel
a Service limit - .005.
b Time required forplunger to leak down .0625 under load of 50 Ibs. using leak-down fluid in tappet.
VALVE SPRINGS
Valve Spring Valve Spring Valve Spring
Compression Pressure Free Length Assembled
Lbs. @ Specified Height (Approximate) Height-
Valve Spring
Out of
Engine Intakeb Exhaust Intake Exhaust Intake Exhaust Square
66-74@ 1.640 66-74@ 1.470
4.9L (300 CID) 1-6 1.96 1.78 161-1.67 1.44-1.50 5/64 (.078)
166-184@ 1.240 166-184@ 1.070
a Pad to retainer.
b Service limit - 10% loss of pressure.
VALVES
Valve Stem to
Guide Clearance· Valve Head Dlameterb
Valve Face Runout
Engine Intake Exhaust Intake Exhaust TIRMaxlmum
4.9L (300 CID) 1-6 .0010-.0027 .0010-.0027 1.769-1.793 1.548-1.572 .0020
a Service clearance - .0055 maximum.
b Valve face angle - 45 0
VALVES (Continued)
Valve Stem Diameter
Standard .015 Oversize .030 Oversize
Engine Intake I Exhaust Intake I Exhaust Intake I Exhaust
4.9L (300 CID) 1-6 .3415-.3423 I .3415-.3423 .3565-.3573 I .3565-.3573 .3715-.3723 I .3715-.3723
ALL RIGHTS RESERVED
CAMSHAFT
Lobe Lift· Camshaft End Play
Camshaft Journal to
Engine Intake Exhaust End Play Service Limit Bearing Clearanceb
4.9L (300 elD) 1-6 .249-.247c .249-.247c .001-.007 .009 .001-.003
a Maximum allowable lift loss - .005.
b Service clearance - .006.
c F-150 4x2 w / 2.47: 1 or 2.75: 1 axle ratio and manual transmission (49S).
CAMSHAFT DRIVE
Camshaft Journal Camshaft Bearing Assembled Gear
Diameter - Standard· Inside Diameter Face Runoutb
Camshaft
Front
Bearing
Engine No.1 No.2 No.3 No.4 No.1 No.2 No.3 No.4 Locatlon c Crankshaft Camshaft
4.9L 2.017- 2.017- 2.017- 2.017- 2.019- 2.019- 2.019- 2.019-
.020-.035 .005 .005
(300 CID) 1-6 2.018 2.018 2.018 2.018 2.020 2.020 2.020 2.020
a Camshaft journal runout - .008 TIR maximum.
b Gear backlash - .004-.010.
c Distance in inches that front edge of the bearing is installed below the front face of the cylinder block.
CYLINDER BLOCK
Distributor
Main Bearing Shaft Head Gasket
Cylinder Bore Bore Bearing Bore Surface Head Gasket Tappet Bore
Engine Diameter· Dlameterb Diameter Flatness Surface Finish Diameter
.003 in any 6
RMS
4.9L (300 CID) 1-6 4.0000-4.0048 2.5902-2.5910 .5155-.5165 inches .8752-.8767
60-150
.006 overall -
a Maximum out-of-round .0015, service limit - .005, maximum taper service limit - .010, cylinder bore surface finish RMS 18-38, bore
taper service limit - .010.
b Crankshaft to rear face of block runout. TIR maximum .005.
CRANKSHAFT AND FLYWHEEL

Main Bearing Main Bearing Main and
Journal Main Bearing Journal Thrust Rod Bearing Main Bearing
Main Bearing Runout Thrust Face Taper Bearing Journal Thrust Face
Journal TIR Runout Maximum Journal FlnlshRMS FlnlshRMS
Engine Diameter· b
Maxlmum . . TIR Maximum Per Inch Length Maximum Maximum
35 Front
4.9L (300 CID) 1-6 2.3982-2.3990 .002 .001 .0005 1.1990-1.2010 12
25 Rear
a Maximum out-of-round - .0006.
b Service limit - .005.
CRANKSHAFT AND FLYWHEEL (Continued)

Flywheel Ring Gear
Lateral Runout TIR
Connecting Flywheel
Connecting Rod Journal Crankshaft Clutch Face
Rod Journal Taper Per Free End Runout Std. Auto. Flywheel Clutch
Engine Diameter· Inch Maximum Playb Assembled Trans. Trans. Face Runout
4.9L (300 CID) 1-6 2.1228-2.1236 .0006 .004-.008 .010 .040 .060 .010

ALL RIGHTS RESERVED
03-01A-79 Engine, 4.9L Six-Cylinder 03-01A·79
CRANKSHAFT BEARINGS
Connecting Rod Bearing to Crankshaft Clearance Main Bearing to Crankshaft Clearance
Selective Fit Selective Fit
Bearing Wall Bearing Wall
Engine Desired Allowable Thickness Std.- Desired Allowable Thickness Std.-
4.9L (300 CIC) 1-6 .0008-.0015 .0009-.0027 .0752-.0757 .008-.0015 .0009-.0028 .0951-.0956
a For .002 undersize add .001 to standard wall thickness.
CONNECTING ROD
Connecting Rod Alignment
Maximum Total Difference
Rod to
Rod Length Crankshaft
Piston Pin Bore Rod Bearing Center to Assembled Side
Engine or Bushing 1.0. Bore 1.0.- Center Twlstb Bend b Clearance c
4.9L (300 CIO) 1-6 .9734-.9742 2.2750-2.2758 6.2082-6.2112 .024 .012 .006-.013
a Connecting rod bearing bore maximum out-of-ground - .006.
b Pin bushing and crankshaft bore must be parallel and in same vertical plane within specified total difference when measured at the ends
of an 8-inch long bar, 4 inches on each side of rod centerline.
c Service limit - .018.
PISTON
Piston to b
Bore Ring Groove Width
Diameter- Clearance Compression
Piston
.003 Selective Pin Bore
Engine Coded Red Coded Blue Oversize Fit Diameter Top Bottom 011
4.9L 3.9982-3.9988 3.9994-4.0000 4.0008-4.0014 .0010-.0018 .9754-.9757 .080-.081 .080-.081 .188-.189
(300 CIO) 1_62
a Measured at the piston pin bore centerline at 90° to the pin.
b Rebuild specification only.
PISTON PIN
Diameter
To Piston Pin To Connecting Rod
Engine Length Standard .001 Oversize .002 Oversize Bore Clearance- Bushing Clearance
4.9L (300 CIO) 1-6 3. 150-3. 170 .9749-.9754 .9760-.9763 .9770-.9773 .0003-.000Sb Interference Fit
a Selective fit.
b Under 8500 Ibs. GVW-.0003-.000S.
PISTON RINGS
Ring Width Compression Side Clearance Compression- Ring Gap Compres810n
Engine Top I Bottom Top I Bottom I 011 Top I Bottom I Ollb
4.9L (300 CIO) 1-6 .0774-.0781 1.0770-.0780 .0019-.0036 I .002-.004 I Snug .010-.020 I .010-.020 I .010-.035
a Service limit - .002 maximum increase in clearance.
b Steel rail.
1995 F-150, F-2S0, F-350, Bronco, F-Super Outy Powertrain, Orivetrain July 1994
ALL RIGHTS RESERVED
OIL PUMP AND OIL CAPACITY

Engine 011 Capacity·
Relief Valve
Spring
Pressure Drlveshaft Relief Valve Rotor Outer Race Innerbto
Lbs.@ to to Assembly to Outer Rotor
Specified Housing Housing End Housing U.S. Imperial Tip
Engine Length Clearance Clearance Clearance Clearance Quarts Quarts Liters Clearance
4.9L 20.6-22.6 .004
.0015-.0030 .0015-.0030 .001-.013 5 4-2 4-7 .012 Maximum
(300 CID) 1-6 @2.49 Maximum
a Add 1 U.S. Quart (or equivalent in imperial quarts or liters) when replacing filter.
b With feeler gauge inserted 1/2 inch minimum and rotor removed from pump housing.
TORQUE LIMITS - 4.9L (300 CID) 1-6 ENGINE

1/4-20 5/16-18 5/16-24 3/8-16 3/8-24 7/16-14 7/16-20 1/2-13 9/16-18
8-12 17-24 19-27 30-43 37-51 55-75 55-81 75-109 116-162
(6-9) (12-18) (14-20) (22-32) (27-38) (40-55) (40-60) (55-80) (85-120)
NOTE: All values are in N·m (Ib-ft) unless otherwise noted. Oil threads with engine oil unless the threads require oil or
water-resistant sealer. The standard torque limits listed are applicable for all functions not listed in the special torque
chart.
PIPE THREADS TORQUE SPECIFICATIONS (Cont'd)

1/8-27 1/4-18 3/8-18 1/2-14 Torque
7-11 (5-8) 17-24 (12-18) 30-44 (22-33) 34-47 (25-35) Item H·m Lb-Ft
Spark Plug to Cylinder Head 14-20 10-15
TORQUE SPECIFICATIONS Valve Rocker Arm Coverb 8-14 70-120
Torque (Lb-In)
Item H·m Lb-Ft Valve Push Rod - Cover to 2-3 18-27

Cylinder Block (Lb-In)
Connecting Rod Nut 55-61 40-45
Water Outlet Housing 17-24 12-18
Cylinder Front Cover 17-24 12-18
Water Pump to Block / Front Cover 17-24 12-18
Cylinder Head Bolts • •
Thermactor Pump Pulley to 12-15 110-130
Damper to Crankshaft 177-203 130-150 Pump Hub (Lb-In)
EGR Valve to Intake Manifold 18-26 13-19 Throttle Body Attaching Nuts 19-27 14-20
Flywheel to Crankshaft 102-115 75-85 Camshaft Thrust Plate to 16-24 12-18
Main Bearing Cap Bolts 82-94 60-70 Cylinder Block
Manifold to Cylinder Head - 30-43 22-32 Distributor Clampdown 24-33 17-25

Intakeb Intake Manifold Vacuum Fittings 8-13 6-10
Manifold to Cylinder Head - 30-43 22-32 Timing Pointer to Front Cover 17-24 12-18
Exhaustb
Thermactor Air Manifold to 19-22 14-16
Exhaust Manifold-to-Muffler 34-49 25-36 Cylinder Head (Nut and Ferrule
Inlet Pipe Assembly)
Oil Filter Insert to Cylinder Block 20-48 15-35 Thermactor Air Check Valve to 22-26 16-19
Oil Filter to Cylinder Block 1/2 turn after gasket Thermactor Air Manifold
contacts sealing surface Pressure Plate and Cover 27-39 22-32
- oiled gasket Assembly to Flywheel
Oil Inlet Tube to Pump 14-20 10-15 Alternator / Thermactor Pump 40-55 30-40
Oil Pan Drain Plug 21-33 15-25 Bracket to Engine (All Except
Bottom Bolt)
Oil Pan to Cylinder Block
b 20-24 15-18
Alternator / Thermactor Pump 53-71 39-53
Oil Pump to Cylinder Block 14-20 10-15 Bracket to Engine (Bottom Bolt)
Oil Inlet Tube to Main Bearing Cap 30-43 22-32 Alternator Pivot Bolt 53-72 39-53
Pulley to Damper Bolt 48-67 35-50 Thermactor Pump Pivot Bolt 40-55 30-41
Rocker Arm Bolt 24-31 17-23 Alternator Adjusting Bolt 40-55 30-41

ALL RIGHTS RESERVED
TORQUE SPECIFICATIONS (Cont'd) SPECIAL SERVICE TOOLS REQUIRED (Cont'd)

Torque Tool Number/
Item N·m Lb-Ft
T61P-6019-B
Thermactor Pump Attaching Bolt 40-55 30-40
Front Cover Aligner
Air Conditioning Compressor to 24-31 18-23
Mounting Bracket Bolts
Power Steering Pump to Mounting 40-55 30-40
Bracket Bolts
T81P-6135-A
Power Steering Pump / Air 40-55 30-40
Piston Pin Remover / Replacer
Conditioning Compressor Bracket
Adapters
to Cylinder Head Bolts
Power Steering Pump / Air 55-70 40-50
Conditioning Compressor Bracket TI1P-I135-A
to Block Bolts and Nuts
T65L-6250-A
Fan Blade to Fan Clutch Bolts 16-24 12-18 Camshaft Bearing Set
Fan Clutch to Water Pump 41-135 30-100
8Follow bolt tightening sequence in this section.

T65L-6306-A
Camshaft Gear Replacing
SPECIAL SERVICE TOOLS REQUIRED Adapter
Tool Number/
Description Illustration T52L-6306-AEE
Crankshaft Sprocket and
T50T-100-A Damper Replacer
~
Impact Slide Hammer
TIOT-1GO-A
TI2L.....AEE
T58L-101-B
~
Puller T88T-670 1-A
Front Cover Seal Remover
T5IL-101-B
T70P-6000
Engine Lifting Bracket T"T~701-A
T58P-6316-D
Crankshaft Damper Remover
T64L-60 11-EA
Cylinder Ridge Reamer T58P-I311-D
T82T-6256-A
Camshaft Gear Puller
TI4L-I011-EA
T73L-6011-A
Cylinder Hone Set
T70P-6049-A
Valve Spring Compressor
T73L-8011-A
T7OP~A
T68P-6135-A
T71 P-6135-P
o
-A1
OO~
-A7 -A2 -AI -M -AI -M T71P..1SH
TIIP~135-A
(Continued)
(Continued)

ALL RIGHTS RESERVED

(Continued)
SPECIAL SERVICE TOOLS REQUIRED (Cont'd) SPECIAL SERVICE TOOLS DESIRED

Tool Number/ Tool Number De8crlptlon
De.crlptlon IIIu8tration
081 L-6002-C Piston Ring Compressor
T74P-6666-A
D79L-6731-A Oil Filter Wrench
Spark Plug Wire Remover
TOOL-6331-E Main Bearing Insert Tool
T74P.....A
ROTUNDA EQUIPMENT
T89T-6701-AH
Rear Oil Seal Replacer Tool Number De8crlptlon
014-00036 Engine Sling
014-00133 Floor Crane
TnT..701-AH
066-00017 Transmission Jack
T70P-6513-A
Tappet Bleed Down Wrench
T87L-6571-BH
Valve Stem Seal Replacer
c==J TI7L-e571-8H
T70P-6B070-B
,

ALL RIGHTS RESERVED
03-018-1 Engines, S.Ol MFI v-a, s.al MFI v-a and S.al MFI lightning v-a 03-018-1
SECTION 03-018 Engines, 5.0L MFI V-8, 5.8L MFI V-8

and 5.8L MFI Lightning V-8
SU8JECT PAGE SU8JECT PAGE
VEHICLE APPLICATION ..•••••••••••.•••••..•.••..•••••.••••••••••03-018-1 IN·VEHICLE SERVICE (Cont'd.)
DESCRIPTION AND OPERATION 011 Level Indicator Tube ••...•••...••••••••••.•••••.•••••••••03-018-43
Camshaft ••..•••••••••••••••.••••••••••••.•••.••••.••••••..•••••.••.•03-018-5 Oil Pan and Oil Pump Screen Cover and
Crankshaft ••••..••••.•..•••••.••••.•.••••••••••.••...••••••.•••••••.03-018-5 Tube •.•.•..•••.••.•••.•••••..•••.••..•.••••............••..•....••03·018-33
Drive 8elt System •••••••••••..••••••••••••••••••••.••••••.•.•••.•03-0 18-6 011 Pump •..••.•.•.•••.•..•••••..••..•••••.•••••••.••••••••••••••••••03-018-34
Engine•••••••..••••••...••.••••••••••••.••••••••••••...••.•..••••••••••03-018-1 Pistons and Connecting Rods •..•....•••..•.•••....•.•••.03-018-37
Engine Cooling System•••••.•••.•.•.••••••••••••••••••••••••••03-018-6 Rocker Arm ••••••••.•••••••••••••••••••••••••••••••••••••.••••••••03·018-18
Engine Identification •.•••••••••••••••••••••••••••••.•••••••••••03.018.4 Sensors•...•••••••••••••••••••••..•••••••..•.•....•••.••••..••••••••03-018-43
Engine Lubrication System ••••...••••.••••••••••••••..••••.•03-018-6 011 Pressure Sender / Switch •••••••••••••••.•••••..••••03-018·43
011 Pan •••••••••••••.••••.•••••••••••••••••••••••.•••.••.•••••••.•••03-018-6 Timing Chains, Sprockets, Tensloner and
011 Pump ••••••••••••••••••••••••••••..••••••••••••.•••••••••••.•.•03-018-6 Guides ••••..••••...•••..••.•••••••.•••••••.••••••••••••••••••••••03-018·28
Exhaust Emission Control System•••••.••••...•••••••••••03-018-5 Valve Cover and Gasket, and Rocker
Induction System •••••••••••••••.•.••••.••••••••••••••••••••••••.03-018-5 Arm •••••...•••.....••••••.••••••••••••••.•••••.••••••••.•••••.•••.•03-018-16
Positive Crankcase Ventilation System •..•••••.•••••••03-018-5 Valve Spring, Retainer and Valve Stem
Valve Train ••••••••••••••••••••••••••.•••••••.••••.••••••••••••••.•••03-018-5 Seal ••••...•.••..•••••••.••••••••••••..•••••...•.••.••...••.••.....03-018-18
IN·VEHICLE SERVICE Valve Tappet, Hydraulic •••...••••••••.••••••..•••••.•••••••.03-018·19
5.8L Engine •••••••••••••••••••••...••••.•••••.••.•••••.•..••.•..••03-018-43 Water Pump •.•..•••.•.••••••••••.•...••.....••..•....•••......•.••03-018-26
Camshaft ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••03-018-30 REMOVAL AND INSTALLATION
Camshaft Rear 8earlng Cover ••.•••••••••••••••••••••••••03-018-41 Camshaft 8earlngs •••••.•••••••.••.••...•••.•.....••......••••03-018-45
Connecting Rod 8earlngs •••.•••••.•.••.•.•••.••••••••••..•03-018-39 Crankshaft ••••••••.••..••.••..••••••..••••••••.••••••..••.•..•.•••03-018-47
Crankshaft Main 8earlngs •••••••••••••••••••..•••....••••.•03-018-35 Engine.•••••...•••..••••••••••••....••••...••••••.....••••.•••••••.••03-018·43
Crankshaft Pulley and/or Damper and/or DISASSEM8LY AND ASSEM8LY
Crankshaft Front Seal ••.•••••....•••..•••••••••.••••••••.03-018-26 Cylinder 810ck ••••..•••.•.•••.••••••...•••.••.•••....•.......••.•03-018-48
Crankshaft Rear 011 Seal ••••.••••••••••••••.••••...•••.••..•03-0 18-40 SU8ASSEM8LIES •••••.••.•.•...•••.••••••••••..••••.•••..••.••03-018-54
Cylinder Head(s) ••••••••••••••.•.•.••••.••••••••••••.•••...••...03-018-24 Cylinder 810ck Assembly .....•.•..•.•••••••••••••.•••.••03-o18·59
Engine Components ••••••••••••••••••••...•••••••••••••••••••••03-018-6 Cylinder 8lock, 8are••••••••••••••••••••••..••....••••.•••.03-018-60
Engine Front Cover •...••••••.•••••••••••••••.•••••.••••..••••03-018-27 Cylinder Head ••••••••.•.•.•••..•.•••••••.••••••••••.•.•••••••03·0 18·54
Exhaust Manifolds ••••••••••••.•••.•••••.••.•••••••••••••••••••03·0 18-31 011 Pump •••••.•••••..••••••••••••••••.•••..••..•••.•••••••••••••03-018-58
Flywheel •••••••.•.••••...•••••••••••••••••••••••••••••.••••••••••••03-018-39 Pistons, Piston Pins and Rings •••••••••••••••••••••.••03-018-56
Intake Manifold ••••••••••.•••...••••.•.•••••••••••••••.••••••.••03-018-20 Valve Tappet, Hydraullc ••..••••••...•.•••••••••.•••••••••03-018·58
Upper.••••••.•••••••.••••••••••••••••.••....••••..••••••••••••••••03-018-20 ADJUSTMENTS
Lower•••••••••••••••••••••..•••.••••••••..•••.•••••••.....•••.....•••03-018-21 Valve Clearance ••.••.••••••...••.••....••••••.••••.•••••••••.••03·018-60
011 8ypass Filter and 011 Filter Mounting SPECIFICATIONS
Insert ••••..••••••••.•••••••••••••••••••••••••••••..•••••.•...••.••03-018-41 General Specifications •....••••...••••••••.••••..••••••••.••03·018·62
011 Filter Cooler and 011 Filter Mounting Insert, SPECIAL SERVICE TOOLS/EQUIPMENT ....••...•.••.••03-018·68
5.8L Lightning Truck Engine ••••••••..•••.•••.••••.••••03-018-41
VEHICLE APPLICATION
F-150, F-250, F-350 and Bronco Vehicles Equipped
with 5.0l or 5.8l MFI Engines and the lightning Truck
Equipped with the 5.8l MFI lightning W-V-8
Engine
The 5.0l (302 CID) V-8, 5.8l (351 CID) V-8 and the
5.8l lightning V-8 engines (6007) have the same
basic design. The cylinder block for these engines is of
special high-grade cast iron, thin-wall construction.
The crankshaft (6303) has five main bearings and is
precision-cast nodular iron. Pistons (6108) are
aluminum alloy, tin plated. Valve rocker arms (6564)
are individually bolt-mounted. The valve tappets
(6500) are hydraulic. These engines are also
equipped with aluminum intake manifold systems.

ALL RIGHTS RESERVED
03-018-2 Engines, 5.0L MFI V-8, 5.8L MFI v-a and 5.8L MFI Lightning v-a 03-018-2
5.0LEnglne
FRONT OF ENGINE
A 15190-0

ALL RIGHTS RESERVED
03-018-3 Engines, 5.0L MFI V-8, 5.8L MFI V-8 and 5.8L MFI Lightning V-8 03-018-3
5.8LEnglne
A10765-D

ALL RIGHTS RESERVED
5.8L Lightning Truck Engine
A17838·A
For quick engine identification, refer to the Safety
Certification Decal.
• The decal is mounted on the LH front door lock face
panel.
• An engine identification label is also attached to the
. engine (6007).
Engine Code Information
The engine code information label, located on the side
~ L
of the right valve cover (6582), contains the engine
build date, engine plant code, the engine code, and the
initial distributor timing.
A10759-C
Part
1 - Engine Build Date
2 - Engine Code
3 - Initial Distributor Timing
4 - Shipping Information
5 - Engine Plant Code -
Cleveland Engine Plant One

ALL RIGHTS RESERVED
03-018-5 Engines, 5.0L MFi V-8, 5.8L MFI V-8 and 5.8L MFI Lightning V-8 03-018-5
Emission Calibration Label These fuel induction systems are mounted on an intake
The emission calibration number label is located on the manifold which in turn is bolted to cast iron cylinder
left side door or left door post pillar. It identifies the heads.
engine calibration number, the engine code number
and revision level.
These numbers are used to determine if parts are
Crankshaft
The crankshaft (6303) is supported on the bottom of
NOTE: It is critical that the engine codes and the
the cylinder block (6010) by five steel backed,
calibration number be used when ordering parts or
over-plated copper-lead crankshaft main bearings
making inquiries about the engine.
(6333). The No.3 bearing insert limits crankshaft end
play and absorbs thrust loads applied to the
crankshaft ends.
CALIBRATION
ErALONNAGE _
CALIBRACI6N Camshaft
2-54E-ROO E8AE.6E061.ABY The camshaft is installed in the cylinder block and is
A10693·B supported on five babbit-lined bearing inserts. Thrust
loads and end play, however, are limited by a
camshaft thrust plate (6269) installed at the front of
the camshaft.
Exhaust Emission Control System

Operation and required maintenance of the exhaust Valve Train
emission control devices used on these engines A hydraulic roller valve tappet (6500), providing
(6007) are covered in the Powertrain automatic lash adjustment, rides on a camshaft lobe
Control/Emissions Diagnosis Manual. 1 and transfers its up-and-down motion to the rocker
arm (6564) through a push rod (6565). The rocker
arms are pedestal-mounted and pivot on rocker arm
seats (6A528) bolted to the cylinder head (6049). The
Induction System valves are arranged alternately intake valve
(6507) / exhaust valve (6505).
The fuel/air mixture needed for burning in the cylinders
is provided by Sequential Fuel Injection (SFt) or
Multiport Fuel Injection (MFI).
Fuel is metered into the air intake stream in Positive Crankcase Ventilation System
accordance with engine demand by eight solenoid
injection valves mounted in the lower intake manifold These engines are equipped with a positive
(9424). closed-type crankcase ventilation system directing the
crankcase vapors to the intake manifold (9424) for
Fuel is supplied from the vehicle's fuel tank by a combustion.
high-pressure electric fuel pump (9350) mounted in the
fuel tank. The fuel is filtered and sent to the fuel
injection supply manifold (90280). A fuel pressure
regulator (ge968) on this fuel injection supply manifold
controls the fuel delivery pressure at a constant 269
kPa (39 psi). The eight fuel injectors are mounted
above each intake runner and are connected in parallel
with the fuel pressure regulator. Excess fuel supplied
by the fuel pump, but not needed by the engine, is
returned to the vehicle fuel tank by a fuel return line.


ALL RIGHTS RESERVED
03-018-6 Engines, S.Ol MFI V-8, S.8l MFI V-8 and S.8l MFI lightning V-8 03-018-6
Engine Lubrication System The oil pan (6675) acts as a reservoir, holding
The engine lubrication system is of the force-feed type lubrication that is pumped through the engine (6007)
in which oil is supplied under full pressure to the by the oil pump after start-up.
crankshaft (6303) and connecting rod bearings
(6211), valve tappets (6500) and camshaft bearings
(6261). From the valve tappets, a controlled volume of
oil is supplied to the rocker arms (6564) through Engine Cooling System
hollow push rods (6565). All other moving parts ar~ The engine cooling system includes a radiator (8005),
lubricated by gravity flow or splash. water thermostat, water pump (8501) and a cooling
fan. Also included in the cooling system is a separate
radiator coolant recovery reservoir (8A080) located
beside the radiator, wh,ch aids in maintaining the
correct volume of coolant.
The wat~r pump is of a conventional design and is
driven by the drive belt (8620).
A10766-C
Drive Belt System
Part Accessories mounted on the front of the engine (6007)
Item Number Description are belt-driven by the crankshaft (6303). A serpentine
drive belt is routed over each accessory pulley and is
1 6622 Oil Pump Screen Cover and driven by a crankshaft pulley (6312) bolted to the
Tube
cr~nkshaft vibration damper (6316). The drive belt is
2 6675 Oil Pan held tight against the drive pulleys by an idler pulley
3 6714 Oil Bypass Filter attached to a tensioner mounted on the right side of
4 6600 Oil Pump the engine. For service procedures, including
5 9278 Oil Pressure Sensor tensioning, refer to Section 03-05.
Oil Pump
The heart of the lubrication system is a full-pressure IN-VEHICLE SERVICE
cast-iron pump. The high capacity "G-rotor" pump is
driven by an oil pump intermediate shaft (6A618) from
the distributor. The pressure is relief-valve controlled.
Engine Components
Engine components shown are typical and provide a
Oil Pan reference for procedures.
The oil pan is a stamped-steel part that bolts to the
bottom of the engine front cover and cylinder block
(6010).
ALL RIGHTS RESERVED
External Engine Components, 5.0L MFI
A15191-D
Part Part
1 8509 Water Pump Pulley 4 6700 Seal - Cylinder Front Cover
2 8501 Water Pump 5 6023 Pointer - Timing
3 8507 Gasket - Water Pump 6 6019 Engine Front Cover
Housing 7 6020 Engine Front Cover Gasket

ALL RIGHTS RESERVED
03-018-& Engines, 5.0L MFI v-a, 5.&L MFI V-& and 5.&L MFI Lightning V-& 03-01B-&
Part Part
8 6010 Cylinder Block 42 6A664 Oil Separator Hose
9 6890 Oil Filter Mounting Insert 43 12106 Cap - Distributor
10 6714 Oil Bypass Filter 44 9B989 Throttle Position Sensor
11 6710 Gasket - Oil Pan 45 9F670 Idle Air Control Gasket
12 6675 Oil Pan 46 9F715 Idle Air Control Valve
13 387549 Bolt 47 9F460 Shield - Intake Manifold
14 6734 Oil Pan Drain Plug Gasket 48 9424 Gasket - Intake Manifold,
15 6730 Oil Pan Drain Plug Upper
16 6049 Head - Cylinder 49 9K461 Manifold - Intake. Upper
17 12A406 Spark Plug Heat Shield 50 9A474 Intake Manifold Vacuum
18 6754 Oil Level Indicator Tube
51 9A474 Fitting - Intake Manifold
19 6750 Indicator - Oil Level
Vacuum Outlet
20 9430 Manifold - Exhaust (RH)
9431 Manifold - Exhaust (LH) Manifold Tube
21 12405 Spark Plug 53 90476 Gasket - EGR Valve
22 6584 Valve Cover Gasket 54 9F483 Valve Assembly - EGR
23 6766 Oil Filler Cap Pressure External
24 6582 Valve Cover (LH) 55 57096 Bolt
25 6375 Flywheel 56 390704 Stud
26 7007 Engine Rear Plate 57 14A1S3 Wiring Harness Retainer
27 9A424 Gasket - Manifold 58 379930 Nut
28 12A699 Knock Sensor 59 9E936 Gasket - Throttle Body
29 12A697 Intake Air Temperature 60 90443 Hose Clip
Sensor 61 9C987 Fuel Vapor Return Hose and
30 9A425 Seal - Manifold Valve Assembly
31 9439 Intake Manifold Gasket 62 9F793 Connecting Hose - Fuel
32 8592 Connection - Water Outlet Rail Front
33 8575 Thermostat - Water 63 9J314 Cap - Protective
34 8255 Gasket - Water Outlet 64 90280 Fuel Injection Supply
Connection. Manifold
35 18599 Hot Water Heater Elbow 65 9C9S8 Regulator Assembly - Fuel
Connection Pressure
36 12A648 Engine Coolant Temperature 66 9F793 Connecting Hose - Fuel
Sensor Rail Rear
37 18599 Hot Water Heater Elbow 67 90280 Manifold - Fuel Injection
Connection Supply (LH)
38 8A565 Cap - Protective 68 9F593 Injector Assembly - Fuel
39 6582 Valve Cover, (RH)· 69 42998-S8 Bolt
40 6A892 Crankcase Ventilation 70 388895 Bolt
Grommet 71 388522-S8 Stud
41 6A666 Positive Crankcase 72 12270 Clamp - Distributor
Ventilation Valve 73 9K461 Manifold - Intake, Lower
(Continued)
ALL RIGHTS RESERVED
Internal Engine Components, 5.0L MFI
A15193-D
Part Part
1 43002 Bolt - Camshaft Retaining 11 391269 Pin -Dowel
2 6278 Washer - Camshaft 12 6250 Camshaft
Sprocket 13 6010 Cylinder Block
3 6278 Washer - Camshaft 14 6A008 Dowel - Cylinder Head to
Sprocket Cylinder Block
4 6256 Sprocket - Camshaft 15 6500 Tappet Assembly - Valve
5 6269 Plate - Camshaft Thrust 16 6565 Rod - Valve Push
6 6267 Bearing - Camshaft Front 17 6A588 Fulcrum Guide
Intermediate 18 6564 Rocker Arm
7 6270 Bearing - Camshaft Rear 19 6A528 Rocker Arm Seat
Intermediate
20 390385 Bolt - Rocker Arm
8 6261 Bearing - Camshaft Front
21 6A516 Retainer - Valve Spring
9 6262 Bearing - Camshaft Center (Exhaust)
10 6263 B.earing - Camshaft Rear
(Continued)
(Continued)
ALL RIGHTS RESERVED
03-018-10 Engines, 5.0L MFI Y-8, 5.8L MFI Y-8 and 5.8L MFI Lightning Y-8 03-018-10
Part Part
22 6518 Key - Valve Spring 46 6334 Cap - Main Bearing
Retainer 47 6329 Cap - Main Bearing
23 6518 Key - Valve Spring 48 391547 Bolt, 1/2-13 x 3.5 -
Retainer Crankshaft Main Bearing
24 6517 Sleeve - Valve Spring Cap (9 Req'd)
Retainer 49 391546 Stud, 3/8-16-7/16-14 x 4.09
25 6514 Retainer - Valve Spring (1 Req'd)
26 6513 Spring - Valve 50 6211 Bearing - Connecting Rod
27 6A517 Valve Stem Seal 51 388907 Key - Woodruff
28 6A517 Valve Stem Seal 52 6337 Crankshaft Thrust Main
29 391413 Bolt, 7/16-14 x 2.49 Bearing
(10 Req'd) 53 6333 Crankshaft Main Bearing
30 391414 Bolt, 7/16-14 x 4.11 54 6148 Partial Piston Ring Set
(10 Req'd) 55 6110 Piston
31 9A487 Valve Assembly - Exhaust 56 6135 Pin - Piston
Air Supply Check 57 6214 Bolt - Connecting Rod
32 9B449 Secondary Air Injection 58 6268 Chain - Timing
Manifold Tube
59 6600 Pump Assembly - Oil
33 12405 Spark Plug
60 6625 Gasket - Oil Pump Inlet
34 6507 Valve - Intake Tube
35 6505 Valve - Exhaust 61 6A618 Oil Pump Intermediate Shaft
36 391275 Bolt - Flywheel to 62 6622 Screen, Tube and Cover
Crankshaft Assembly - Oil Pump
37 6375 Flywheel 63 6306 Sprocket - Camshaft
38 7007 Engine Rear Plate 64 6K338 Damper Assembly -
39 6701 Crankshaft Rear Oil Seal Crankshaft
40 6303 Crankshaft 65 6312 Pulley Assembly -
41 6333 Crankshaft Main Bearing Crankshaft
42 6325 Cap - Main Bearing 66 6378 Washer - Crankshaft Pulley
43 6A339 Bearing - Main Thrust Retaining
44 6327 Cap - Main Bearing 67 388813 Bolt - Crankshaft Pulley
Cap - Main Bearing Retaining
45 6330
(Continued)
ALL RIGHTS RESERVED
03-01B-11 Engines, 5.0L MFI V-8, 5.8L MFI V-8 and 5.8L MFI Lightning V-8 03-01B-11
IN-VEHICLE $ERVICE (Continued)
External Engine Components, 5.8L MFI
:.'.~
.. "
~. W
A15185-E
Part Part
1 14A163 Retainer - Wiring Harness 4 9K461 Manifold - Intake
2 9F483 EGR External Pressure Valve 5 90446 Fitting and Cap Assembly
3 90476 Gasket - EGR Valve (Intake Manifold Vacuum
Assembly Outlet)
1995F-150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain July 1994
ALL RIGHTS RESERVED
Part Part
6 9A474 Intake Manifold Vacuum 52 8548 Water Bypass Tube Or Hose
Outlet Fitting and Cap 53 388522-S8 Stud
7 9J459/9S448 EGR Vacuum Regulator 54' 6M025 Pointer - Timing
8 12A310 Coil - Assembly 55 6010 Cylinder Block
9 9F792 Manifold - Fuel Injection 56 9439 Intake Manifold Gasket
Supply 57 9A425 Seal - Manifold Front
10 9A487 Secondary Air Injection 58 9A424 Seal - Manifold Rear
Check Valve
59 6A372 Plate Assembly - Engine
11 17K004 Lifting Eye Rear
12 9B449 Secondary Air Injection 60 6375 Flywheel Assembly
Manifold Tube
61 E800691-S200 Bolt
13 9F593 Injector
62 N804758-S2 Nut
14 6379 Bolt
63 390948-S26 Stud
15 6766 Oil Filler Cap
64 390589-S8 Stud
16 379058-S7 Bolt
65 9J444 Bracket
17 56124-S2 Bolt
66 12A697 Sensor Assembly - Intake
18 6582 Valve Cover (LH) Air Temperature
19 6584 Valve Cover Gasket 67 10884 Water - Temperature
20 6065 Bolt Sender
21 6065 Bolt 68 18B402 Tube - Heater Hot Water.
22 12405 Spark Plug 69 9H486 Gasket - Intake Manifold
23 9431 Manifold - Exhaust (LH) Upper
24 12A406 Spark Plug Heat Shield 70 12A648 Sensor Assembly - Engine
25 N803949-S2 Stud Coolant Temperature
26 17A084 Lifting Eye 71 9K461 Lower Intake Manifold
Assembly
27 383745 Nut
72 8255 Gasket - Water Outlet
28 389201 Stud Connection
29 6049 Head - Cylinder
73 8575 Thermostat - Water
30 6884 Oil Filter Adapter Connection - Water Outlet
74 8592
31 6L626 Oil Cooler Insert Manifold - Exhaust (RH)
75 9430
32 6051 Head Gasket
76 12270 Clamp - Distributor
33 6890 Insert - Oil Filter Mounting
77 12A217 Adaptor Assembly -
34 6A642 Oil Cooler Assembly (Distributor Base)
35 6714 Oil Bypass Filter 78 9F485 EGR Valve Tube to Manifold
36 6894 Oil Filter Adapter Mounting Connector
Bolt 79 12106 Cap - Distributor
37 6710 Gasket - Oil Pan 80 90477 EGR Valve to Exhaust
38 6675 Pan Assembly - Oil Manifold Tube
39 6734 Gasket - Oil Pan Drain Plug 81 6582 Valve Cover (RH)
40 6730 Plug - Oil Pan Drain 82 9B989 Position Sensor - Throttle
41 357144-S Bolt 83 6A892 Crankcase Ventilation
42 30266-S Bolt Grommet
43 6K741 Oil Cooler Adapter 84 6A886 Extension Tube - PCV
44 6020 Engine Front Cover Gasket 85 6762 Elbow-PCV
45 6019 Engine Front Cover 86 389772 Clamp
46 6700 Crankshaft Front Seal 87 6A666 Positive Crankcase
Gasket - Water Pump Ventilation Valve
47 8507
Housing 88 6A664 Oil Separator Hose
48 8501 Pump Assembly - Water 89 9E926 Throttle Body Assembly
49 8509 Pulley - Water Pump 90 9E936 Throttle Body Gasket
50 42998-S8 Bolt 91 9F670 Gasket - Air By-Pass Valve
51 300958-S Bolt 92 390358-S8 Bolt
(Continued)
ALL RIGHTS RESERVED
03-018-13 Engines, 5.0L MFI V-8, 5.8L MFi V·8 and 5.8L MFI Lightning V·8 03-018·13
External Engine Components, 5.8L Lightning Truck Engine

ALL RIGHTS RESERVED
03-018-14 Engines, 5.0l MFI v-a, 5.al MFI v-a and s.al MFI lightning v-a 03-018-14
Part Part
Item NUlTlber Description Item Number Description
1 8509 Pulley, Water Pump 52 9431 E~haust Manifold, Left
2 8501 Water Pump Assembly 53 9448 Gasket

3 8507 Gasket, Water Pump 54 12405 Spark Rlug
Housing 55 391280 Bolt
4 6700 Crankshaft Front Seal 56 391279 Bolt
5 6K741 Oil Cooler Adapter Assembly 57 6584 Valve Cover Gasket
6 6019 Engine Front Cover 58 6582 Va,v~ Cover
7 6020 Engine Front Cover Gasket 59 390822 Screw
8 6023 Pointer, Timing 60 6051 Gasket, Cylind~r Head
9 388522-S8 Stud 61 6754 Tube, Oil Level Indicator
10 388895 Bolt 62 6A372 Plate, Engine, Rear
11 12A310 Coil Assembly 63 6375 Flywheel Assembly
12 45357 Nut 64 391284 Bolt
13 389772 Clamp 65 56124 Bolt
14 8A506 Heater Hose 66 9B449 Secondary Air Injection
15 383522 Clamp Manifold Tube
16 12127 Distributor Assembly 67 9A487 Secondary Air Injection
Adapter, Distributor Check Valve
17 12A217
Assembly 68 90930 Wiring Assembly, Fuel
Distributor Cap Charging
18 12106
Clamp 69 90280 Fuel Injection Supply
19 12270
Manifold
20 42955 Screw
70 9F593 Fuel Injector
21 12280 Wire Set, Right
71 387564 Nut
22 12281 Wire Set, Left
72 56703 Bolt
23 12298 Ignition Coil to Distributor
High Tension Wiring 73 57636 Bolt
Exhaust Manifold, Right 74 8592 Water Hose Connection
24 9430
Cap, Oil Fill 75 6N789 Oil Cooler Return Tube
25 6766
Gasket
26 6582 Valve Cover
76 8575 Water Thermostat
27 6049 Head Assembly, Cylinder
77 12A648 Engine Coolant Temperature
28 9439 Intake Manifold Gasket (ECT) Sensor
29 9A425 Seal, Intake 78 18A568/18559 Coolant Tree
Manifold-to-Block, Front
79 18K396 Tube, Heater Water
30 9A424 Seal, Intake
Manifold-to-Block, Rear 80 8A565 Shield
Oil Level Indicator 81 373724 Nipple
31 6750
82 391273 Elbow
32 6A008 Dowel
83 87717 Plug
33 6010 Cylinder Block
84 9K461 Manifold, Upper Intake
34 9278 Sender, Oil Pressure
Gasket, Oil Pan 85 390653 Bolt
35 6710
Oil Pan 86 9E434 Cover
36 6675
87 390652 Screw
37 390658 Bolt
38 6730 Plug, Oil Pan
39 6734 Oil Pan Drain Plug Gasket
89 90446 Vacuum Fitting
40 6890 Insert, Oil Filter Mount
90 391136 Bolt
41 6881 Oil Filter Adapter
91 9H486 Intake Manifold Upper
42 6A642 Cooler, Oil Gasket
43 6894 Bolt 92 6L678 Baffle
44 6L626 Insert, Oil Filter 93 10884 Water Temperature Sender
45 6714 Oil Bypass Filter 94 12A697 Intake Air Temperature (lAT)
46 12A406 Spark Plug Heat Shield Sensor
47 382951 Bolt 95 388058 Bolt
48 383745 Nut 96 9J447 Manifold, Lower Intake
49 17A084 Lifting Eye, Front 97 373724 Nipple
50 383745 Nut 98 376785 Nut
51 389201 Stud 99 376838 Nut
ALL RIGHTS RESERVED
03-018-15 Engines, 5.0l MFI V-8, 5.8l MFI v-a and 5.8l MFI lightning V-8 03-018-15
Part Part
100 9F483 EGR External Pressure Valve 107 9H474 EGR Spacer
101 90476 EGR Valve Gasket 108 9E933 Gasket
102 6C342 Hose Assembly, PCV 109 6758 Hose, Fresh Air
103 68892 Elbow 110 383520 Clamp
104 6A666 PCV Valve Assembly 111 9F476 Hose
105 6A892 Crankcase Ventilation 112 9J459 EGR Vacuum Regulator
Grommet 113 98448 Valve and Bracket Assembly
106 9E464 Gasket 114 9E926 Throttle Body Assembly
(Continued) 115 42998-S8 Bolt
Internal Engine Components, 5.8l MFI and 5.8l MFI lightning Truck Engine
A15197·E
ALL RIGHTS RESERVED
Part Part
1 43002 Bolt 33 6148 Ring Set - Piston
2 6278 Washer - Camshaft 34 6110 Piston Assembly
Sprocket 35 6135 Pin - Piston
3 6A295 Eccentric - Camshaft Fuel 36 6214 Bolt - Connecting Rod
Pump 37 6333 Bearing - Crankshaft Main
4 6256 Sprocket - Camshaft 38 6337 Bearing - Crankshaft Main
5 6269 Plate - Camshaft Thrust 39 6200 Rod Assembly -
6 6267 Bearing - Camshaft Front Connecting
Intermediate 40 394230 Key - Woodruff
7 6270 Bearing - Camshaft Rear 41 6211 Bearing - Connecting Rod
Intermediate Bearing - Main Thrust
42 6A339
8 390392 Bolt - Camshaft Thrust
43 6300 Crankshaft Assembly
Plate
44 6701 Packing Seal - Crankshaft
9 6261 Bearing - Camshaft Front
Rear
10 6262 Bearing - Camshaft Center Plate - Engine Rear
45 6A372
11 6263 Bearing - Camshaft Rear Flywheel Assembly
46 6375
12 6250 Camshaft Bearing - Crankshaft Main
47 6A338
13 6010 Cylinder Block (Except Center)
14 6500 Tappet Assembly - Valve 48 6325 Cap - Main Bearing
14A 6C515 Plate Retainer Valve Tappet Guide 49 6327 Cap - Main Bearing
14B 6K512 Guide Plate (8 Places) 50 6330 Cap - Main Bearing
15 6565 Rod - Valve Push 51 6329 Cap - Main Bearing
16 6564 Rocker Arm 52 390602 Bolt - Crankshaft Main
17 6A528 Rocker Arm Seat Bearing Cap (9 Required)
18 390385 Bolt - Rocker Arm 53 386562 Stud - 3/8-16-1/2-13 x
19 6A516 Retainer / Rotator - Valve 4.70 (1 Required)
Spring (Exhaust) 54 6210 Cap - Main Bearing
20 6518 Key - Valve Spring 55 6306 Sprocket - Crankshaft
Retainer (Exhaust) 56 6316 Damper Assembly -
21 6518 Key - Valve Spring Crankshaft
Retainer (Intake) 57 6312 Pulley Assembly -
22 6517 Sleeve - Valve Spring Crankshaft
Retainer 58 6378 Washer - Crankshaft Pulley
23 6514 Retainer - Valve Spring Retaining
(Intake) 59 376706 Bolt
24 6513 Spring - Valve 60 6268 Chain - Timing
25 6A517 Valve Stem Seal 61 6600 Pump Assembly - Oil
26 12405 Spark Plug 62 6625 Gasket - Oil Pump Inlet
27 6507 Valve - Intake Tube
28 6505 Valve - Exhaust 63 6622 Oil Pump Screen Cover and
29 6049 Head - Cylinder Tube
30 6513 Spring - Valve 64 6055 Bolt - 1/2-13 x 4
Fulcrum Guide (10 Required)
31 6A588
Gauge Assembly - Oil 65 6055 Bolt - 1/2-13 x 2.5
32 9278
Pressure Engine (10 Required)
66 391284 Bolt
(Continued)
Valve Cover and Gasket, and Rocker Arm 2. Remove crankcase ventilation tube (6758)
assembly.
SPECIAL SERVICE TOOL(S) REQUIRED 3. Remove lifting eye for right valve cover (6582)
Description Tool Number removal.
Spark Plug Wire Remover T74P-6666-A 4. Remove lifting eye from left exhaust manifold
(9430) for left valve cover removal (5.8l
Removal lightning only).
1. Remove engine air cleaner (ACl)(9600) and air
cleaner outlet tube (98659) assembly.
ALL RIGHTS RESERVED
)3-018-17 Engines, 5.0L MFI V-8, 5.8L MFI V-8 and 5.8L MFI Lightning V·8 03·018·17
5. If equipped with air conditioning, remove drive Valve Cover nghtenlng Sequence
belt and compressor-to-bracket bolts and
VALVE
position compressor out of way (all except 5.8l COVER-6A505
Lightning). (ECONOLINE)
6. Disconnect spark plug wires from spark plugs
(12405) by grasping, twisting and pulling the VALVE
ARM COVER
molded cap using Spark Plug Wire Remover 6582
T74P-6666-A. Position wires out of way.
GASKET
6584
TWIST AND PULL

B3498-E
7. Remove upper intake manifold (9424) as

described in this section.
8. Remove nuts securing wiring harnesses to valve
covers, and position wiring harnesses out of way. A15264-B
9. Remove vacuum harness and electrical
connectors to vacuum solenoids mounted on Part
valve covers and position out of way (all except Item Number Description
5.8L Lightning). 1 6A505 Valve Cover
10. Disconnect secondary air injection manifold tubes 2 6584 Gasket
(98449) from canister or the chassis and position 3 6766 Oil Cap Assembly
out of way.
2. Position the valve cover on the' cylinder head
11. Remove valve cover attaching bolts and remove (6049). Install the cover bolts and tighten to
valve covers. 16-20 N·m (12-15 Ib-ft). Wait two minutes, then
Installation tighten bolts again to same specification.
1. Clean and inspect gasket surfaces. Inspect the 3. Install vacuum harness bracket and attaching nut,
gasket sealing surface for damage and distortion if removed. lighten to 17-24 N·m (13-18Ib-ft).
due to overtightening of the bolts. Repair and 4. Connect vacuum harness and electrical
straighten as required. Place the new valve cover connectors to the vacuum solenoids on the valve
gasket (6584) in the valve cover, making sure covers (all except 5.8 Lighting).
that the tabs of the gasket engage the notches
provided in the valve cover. 5. Position wiring harnesses over valve covers and
secure onto valve cover studs and install
attaching nuts.
6. Install upper intake manifold as described in this
section.
7. Connect secondary air injection manifold tube.
8. Position and connect spark plug wires to spark
plugs.
9. Position air conditioning compressor and install
compressor-to-bracket bolts, if equipped.
10. Install drive belt. Refer to engine compartment
belt routing decal.
11. Reinstall lifting eye(s).
12. Install crankcase ventilation tube assembly.
ALL RIGHTS RESERVED
13. Install engine air cleaner and air cleaner outlet Removal
tube assembly. Broken valve spring (6513) or damaged valve stem
14. Check and fill oil level as required. Check and fill seals (6571) and retainers may be replaced without
cooling system as required. Start engine (6007) removing the cylinder head (6049), provided damage
and check for leaks. to valve or valve seat has not occurred.
1. Remove valve cover (6582) as outlined.
2. Remove the applicable spark plug ( 12405) and
bring the piston (6108) to the top of the bore to
Rocker Arm
prevent accidental loss of the valve into the
Removal cylinder.
1. Remove rocker arm attaching bolt, rocker arm 3. Remove the valve rocker arm fulcrum bolts,
seat (6A528), rocker arm (6564) and rocker arm rocker arm seats (6A528), rocker arms (6564)
fulcrum guide (6A588). and push rods (6565) from the applicable
cylinder.
4. NOTE: Failure of the air pressure to hold the
valve(s) in the closed position is an indication of
valve seat damage and requires removal of the
cylinder head.
Install an air line with an adapter in the spark plug
hole and apply air pressure to the cylinder.
5. Install the fulcrum bolt and position Valve Spring
Compressor Tool T70P-6049-A as shown.
Compress the valve spring and remove the valve
spring retainer key (6518), sleeve, retainer or
rotator and valve spring.
A487D-C
Part
1 390385 Attaching Bolt
2 6A528 Rocker Arm Seat
3 6564 Rocker Arm
4 6A588 Rocker Arm Fulcrum Guide
5 6049 Threaded Pedestal
(Part of Cylinder Head)
Installation
ESB-M 1C93-A to the top of the valve stem, the
rocker arm seat and socket.
2. Install the rocker arm fulcrum guide, rocker arm,
fulcrum and bolt. Tighten to 24-34N·m (18-25
Ib-ft).
A10098-B
6. Remove and discard the valve stem seal.

Valve Spring, Retainer and Valve Stem Seal 7. If air pressure has forced the piston to the
bottom of the cylinder, any removal of air
SPECIAL SERVICE TOOL(S) REQUIRED pressure will allow the valve(s) to fall Into the
Description Tool Number cylinder. A rubber band, tape or string wrapped
around the end of the valve stem will prevent this
Valve Spring Compressor Tool T70P-6049-A condition and will still allow enough travel to
check the valve for binds.
ALL RIGHTS RESERVED
03-018-19 Engines, 5.0l MFI V-8, 5.8l MFI V-8 and 5.8l MFI lightning V-8 03-018-19
8. Inspect the valve stem for damage. Rotate the Valve Tappet, Hydraulic
valve and check the valve stem tip for eccentric Before replacing a hydraulic valve tappet (6500) for
movement during rotation. Move the valve up and noisy operation, verify the noise is not caused by
down through normal travel in the valve guide and improperly adjusted valve-to-rocker arm clearance or
check the stem for binds. If the valve has been by worn rocker arms (6564) or push rods (6565).
damaged, it will be necessary to remove the
cylinder head. Refer to cylinder head repair Removal
procedures in this section. 1. Remove the intake manifold (9424) and related
Installation parts as described in this section.
1. If the condition of the valve proved satisfactory, 2. Disconnect secondary air injection manifold tube
lubricate the valve stem with Motorcraft (9B449) at the secondary air injection pump (AIR
XO-10W3Q-aSp or DSP engine oil or equivalent pump)(9A486) and place it out of the way.
meeting Ford specification ESE-M2C153-E. Hold 3. Remove the valve cover (6582), then loosen the
the valve in the closed position and apply air valve rocker arm fulcrum bolts and rotate the
pressure within the cylinder. rocker arms to the side.
2. Install a new valve stem seal on the valve guide. 4. Remove the push rods in sequence so that they
Valve stem seals must be bottomed on guide. can be installed in their original positions.
Place the valve spring in position over the valve
and install the valve spring retainer and sleeve.
Compress the valve spring and install the valve • &C>~QO.OOO'9D
tool and fulcrum bolt.
A10373-1 A
5. Remove the valve tappets and place them in a
rack so that they can be installed in their original
bores.
SEAL If necessary to disassemble a valve tappet, refer
to Hydraulic Valve Tappet in Subassemblies,
Disassembly and Assembly in this section.
Installation
1. NOTE: Valve tappets and bores are to be
lubricated with engine oil of the quality
AIR LINE
A10099-B
recommended in the Owner Guide before
installation.
3. Lubricate the push rod ends with Multi-Purpose Clean the external surfaces and install the valve
Grease DOAZ-19584-AA or equivalent meeting tappets in the bores from which they were
Ford specification ESB-M 1C93-A and install the removed using Hydraulic Tappet Puller
push rod. Apply Multi-Purpose Grease T70L-6500-A. If a new valve tappet is being
DOAZ-19584-AA or equivalent meeting Ford installed, check the new valve tappet for a free fit
(~ specification ESB-M 1C93-A to the tip of the valve in the bore in which it is to be installed. Lubricate
stem. the valve tappet and bore with recommended
4. Apply Multi-Purpose Grease DOAZ-19584-AA or quality engine oil before inserting the valve
equivalent meeting Ford specification . tappet.
ESB-M 1C93-A to the rocker arms and rocker 2. Lubricate the ends of the push rods with
arm seats. Install the rocker arms, rocker arm Multi-Purpose Grease DOAZ-19584-AA or
seats and fulcrum bolts. lighten to 24-34 N·m equivalent meeting Ford specification
(18-25Ib-ft). ESB-M 1C93-A and install the push rods in their
5. Turn off the air and remove the air line and original positions. Apply Multi-Purpose Grease
adapter. Install the spark plug and connect the DOAZ-19584-AA or equivalent meeting Ford
spark plug wire. specification ESB-M 1C93-A to the valve stem tip.
6. Clean and install the valve cover as described in 3. Lubricate the rocker arms and rocker arm seats
this section. (6A528) with Multi-Purpose Grease
specification ESB-M1C93-A and position the
rocker arms over the push rod. lighten rocker
arm fulcrum bolts to 24-34 N·m (18-25Ib-ft).
ALL RIGHTS RESERVED
03-018-20 Engines, 5.0l MFI v-a, 5.al MFI v-a and 5.al MFI lightning v-a 03·018·20
4. Install the valve covers as described in this 9. Remove six upper intake manifold retaining bolts.
section. 10. Remove upper intake manifold and throttle body
5. Reconnect secondary air injection manifold tubes. as an assembly from lower intake manifold.
6. Install the intake manifold as described in this Installation
section.
1. Clean and inspect the mounting faces of the lower
and upper intake manifolds.
2. Position new gasket on lower intake mounting
Intake Manifold face. The use of alignment studs may be helpful.
3. Install upper intake manifold and throttle body
Upper assembly to lower intake manifold making sure
Removal gasket remains in place (if alignment studs are
not used).
1. Disconnect electrical connectors at idle air
control valve (lAC valve)(9F715), throttle position 4. Install six upper intake manifold retaining bolts
sensor (TP sensor)(98989) and EGR position and tighten to 17-24 N·m (13-18Ib-ft).
sensor. 5. Install upper intake support bracket to upper
2. CAUTION: When disconnecting throttle manifold attaching bolt.
cable from ball stud, use a screwdriver or 6. Install EGR valve to exhaust manifold tube.
similar tool close to the stud and pry slowly. Tighten flange nuts to 41-54 N·m (30-40 Ib-ft).
Pulling by hand may damage the cable.
7. Install canister purge lines to fittings on throttle
Disconnect throttle linkage at throttle ball. body.
Disconnect 4R70 (5.0l only) or C6 (5.8l only)
transmission linkage from throttle body (9E926). 8. Connect water heater lines to the throttle body.
Remove two bolts securing accelerator cable 9. Connect PCV hose to rear of upper intake
bracket (9723) to intake. Position accelerator manifold.
cable bracket with cables out of way.
10. Connect vacuum lines to vacuum tree, EGR
3. Disconnect upper intake manifold vacuum fitting external pressure valve and fuel pressure
connections by disconnecting all vacuum lines to regulator.
vacuum tree, vacuum lines to EGR external
11. Position accelerator cable bracket with cables to
pressure valve (9F483) and vacuum line to fuel
upper intake manifold. Install two retaining bolts
pressure regulator (9C968).
and tighten to 11-13 N·m (8-10 Ib-ft); 19-26 N·m
4. Disconnect PCV system by disconnecting hose (14-19Ib-ft) 5.8l HO lightning only. Connect
from fitting on rear of upper intake manifold throttle cable and transmission cable to throttle
(9424). body.
5. Remove canister purge line(s) from fitting(s) on 12. Connect electrical connectors at idle air control
throttle body. valve, throttle position sensor and EGR position
6. Disconnect water heater lines from the throttle sensor.
body. 13. If lower intake manifold was removed, fill and
7. Disconnect EGR valve to exhaust manifold tube bleed cooling system as outlined. Refer to
(9D477) from EGR external pressure valve by Section 03-03.
removing flange nut.
8. Remove bolt from upper intake support bracket
to upper intake manifold.
ALL RIGHTS RESERVED
03-018-21 Engines, 5.0l MFI v-a, 5.al MFI v-a and 5.al MFI lightning v-a 03-018-21
Intake Manifold Lower

Removal
1. Remove upper intake manifold (9424), throttle
body (9E926) and air cleaner assembly as
outlined in this section, prior to lower intake
manifold removal.
2. Drain cooling system.
3. Remove distributor assembly, distributor cap
(12106) and wires. Mark position of distributor
and rotor during removal so that they can be
installed in their original position.
4. Disconnect the electrical connections at the
engine coolant temperature sensor (EeT
sensor)( 12A648), engine temperature sending
unit, intake air temperature sensor (JAT
sensor)( 12A697), sensor (49 state), electrical
vacuum regulator and secondary air injection
solenoids.
5. Disconnect the injector wiring harness from main
harness assembly.
6. NOTE: The plated stud and ground wire must be
installed in the same position from which it was
removed.
Remove heated oxygen sensor ground wire from
intake manifold stud.
5.8lSHOWN, 7. Perform all preservice procedures as outlined to
5.0l TYPICAL relieve any fuel system pressure as described in
Section 03-04A.
~ FRONT OF ENGINE
8. Disconnect fuel supply and return line retaining
FLAT SIDE clips. Disconnect fuel supply and return lines from
fuel rails, using Disconnect Tool D87L-9280-A
PARALLEL TO ~ and D87L-8280-B or equivalent. Refer to Fuel
- - OF CRANKSHAFT Supply Manifold Assembly in t~is section.
± 10°
9. Remove upper radiator hose (8260) from water
VIEW A hose connection (8592).
V5302-G 10. Remove water bypass tube or hose (8548).
11. Remove heater outlet hose at intake manifold.
Part 12. Remove nut securing coil bracket and move
Item Number Description bracket out of way.
1 390358 Bolt (5 Req'd) 13. Remove intake retaining bolts and studs, noting
2 390249 Screw location of studs and bolts.
Outlet Fitting and Cap 14. Remove lower intake manifold assembly.
Gasket
6 9A474 Connector
(12-18 Lb-Ft)
(6-10 Lb-Ft)
ALL RIGHTS RESERVED
Lower Intake Manifold
Part Part
1 - ECT Sensor Location 6 - Fuel Return Tube
(Part of 9K461) (Part of 9F792 Assembly)
2 9F593 Fuel Injector 7 - IAT Sensor Location
3 9C968 Fuel Pressure Regulator (49 State) (Part of 9K461)
Assembly 8 - Water Temperature Sender
4 90280 Fuel Injection Supply Location (Part of 9K461)
Manifold 9 - Pressure Relief Valve
5 90930 Wiring Harness (Part of 9F792)
(Continued)
Installation
intake manifold and cylinder block surfaces.
Refer to Section 03-00.
2. Apply 1.6mm (1 / 16-inch) bead of Silicone
Rubber D6AZ-19562-BA sealer or equivalent
meeting Ford specification ESB-M4G92-A to the
end seals (junction).
A3715-N
Part
1 - Sealer (4-Joints)
2 6049 Cylinder Head
3 9439 Intake Manifold Gasket
4 9A424/9A425 Intake Manifold Seal
5 - Sealer (4-Seal Ends)

ALL RIGHTS RESERVED
3. NOTE: This sealer sets up within 15 minutes after Lower Intake Manifold
application. To assure effective sealing,
assembly should proceed promptly.
NOTE: The gaskets must be interlocked with the
seal tabs.
Install end seals on the cylinder block (6010) and
new gaskets on the cylinder heads (6049).
FRONT OF ENGINE
GASKETS
END SEAL
9A424
•
V4793·B
4. Install two locator pins into opposite corners.

FRONT OF ENGINE
5. Carefully lower intake manifold assembly into
position. V4792-F
Part
Item Number De8criptl~n
1 - Nut (Part of 9K461)
2 9F792 Fuel Rail
3 - Stud (Part of 9K461)
4 - Locating Pin (4 Places)
(Part of 9K461)
5 9K461 Lower Intake Manifold
6 - 80lt (Part of 9K461)
7 - Clip (Part of 9K461)
(8-10 Lb-Ft)
(23-25 Lb-Ft)
6. Install intake manifold bolts and studs. Tighten all

bolts and studs using the sequence shown in
three steps as follows:
Step 1. Tighten all to 11 N·m (Blb-ft).
Step 2. Tighten all to 22 N·m (16Ib-ft).
Step 3. Tighten all to 31-34 N·m (23-25 Ib-ft).
ALL RIGHTS RESERVED
Tightening Sequence 3. Lift tensioner and remove drive belt. Remove the
engine air cleaner intake tube (9A624) from the
left cylinder head assembly.
If the left cylinder head is being removed, remove
the air conditioning compressor / power steering
bracket at the front of the cylinder head,
complete with accessories. Remove oil level
dipstick (6750) and oil level indicator tube (6754)
asse,mbly and speed control bracket, if so
equipped.
4. Disconnect the generator wiring harness and
secondary air injection pump hoses, if the right
cylinder head is to be removed. Remove the three
bolts attaching the generator / secondary air
injection pump bracket to the cylinder head.
Remove the generator, secondary air injection
7. Install coil and solenoid bracket to intake manifold pump (AIR pump)(9A486) and bracket as an
studs and exhaust manifold stud. Install retaining assembly from the engine (6007).
nuts and tighten to 6-7 N·m (53-62Ib-in). 5. Disconnect the exhaust manifold(s) from the
8. Install upper radiator hose and water bypass tube muffler inlet pipe(s).
or hose to water hose connection. 6. Loosen the rocker arm seat bolts so that the
9. Install heater outlet hose to intake manifold. rocker arms (6564) can be rotated to the side.
Tighten to 3-4 N·m (27-34Ib-in). Remove the push rods (6565) in sequence so
that they may be installed in their original
10. Connect fuel supply and return lines to fuel positions.
injection supply manifold (90280). These are
push-connect fittings. Connect fuel line retaining
clips. • & 0 0 0 0 • 0 0 0 , '9 9
11. Connect the electrical connectors to engine
coolant temperature sensor, intake air
temperature sensor (49 state) engine
temperature sending unit, electrical vacuum
regulator and secondary air injection solenoids.
12. Install distributor assembly in the proper position
as noted during removal. Install distributor cap
and wires. A10373-tA
13. Install upper intake manifold as outlined. 7. Disconnect the secondary air injection manifold
14. Fill and bleed the cooling system. Refer to tubes (98449) at the check valves and plug the
Section 03-03. check valve.
15. Perform all post-service procedures as outlined in 8. Install the cylinder head holding fixtures. Remove
Section 03-04A or 03-040. the cylinder head attaching bolts and lift the .
cylinder head off the cylinder block (6010).
'Remove and discard the head gasket (6051).
Installation
'Cylinder Head(s) 1. Clean the cylinder head, intake manifold, valve
If a cylinder head (6049) is to be replaced, follow the cover and cylinder head gasket surfaces. If the
procedures under Subassemblies, Cylinder Head in cylinder head was removed for a head gasket
Disassembly and Assembly, and transfer all valves, replacement, check the flatness of the cylinder
valve spring (6513), spark plugs (12405), etc., to the head and block gasket surfaces. Refer to Section
new cylinder head. Clean and inspect all parts, and 03-00.
reface the valves. Refer to Section 03-00. Check all 2. NOTE: Do not apply sealer to a composition
assembly clearances before assembling the new or gasket.
used parts to the new cylinder head.
A specially treated composition gasket is used.
Removal Position the new head gasket over the cylinder
1. Remove the upper and lower intake manifold dowels on the cylinder block. Position the
(9424). Refer to Upper ~nd Lower Intake cylinder head on the cylinder block and install the
Manifold, Removal in this section. . attaching bolts. Remove the holding fixtures.
2. Remove the valve cover (6582).
ALL RIGHTS RESERVED
3. The cylinder head bolts are tightened in two steps

for a1l5.8l engines, and three steps
(torque-to-yield method) for the 5.0l engine.
• For all 5.8l engines, tighten head bolts as
follows:
- lighten all bolts in sequence to
129-142 N·m (95-105Ib-ft).
- lighten all bolts in sequence to
142-152 N·m (105-112 Ib-ft).
• 5.0l engine
- lighten all bolts in sequence to 34-47 N·m
(25-35 Ib-ft).
- lighten all bolts in sequence to 61-75 N·m
(45-55 Ib-ft).
- Turn all bolts in sequence an additional A487D-C
85-95 degrees.
When cylinder head bolts have been tightened Part
following this procedure, it is not necessary to Item Number Description
retighten the bolts after extended operation. 1 - Attaching Bolt (Part of 6564)
However, the bolts may be checked and 2 6A528 Rocker Arm Seat
retightened if desired. 3 6564 Rocker Arm
4 6A588 Rocker Arm Fulcrum Guide
5 6049 Threaded Pedestal
(Part of Cylinder Head)
7. Position a new gasket(s) on the muffler inlet

pipe(s), if so required. Connect the exhaust
manifold(s) at the muffler inlet pipe(s). lighten the
nuts to 33-49 N·m (24-36 Ib-ft).
8. If the right cylinder head was removed, install the
secondary air injection pump generator bracket
and accessories and air cleaner on the right
cylinder head. Refer to Section 03-05 to install
A10374-1A drive belt and auto tensioner.
4. NOTE: Do not attempt to straighten push rods. If the left cylinder head was removed, install the
Clean the push rods in a suitable solvent. Blow power steering and air conditioning compressor
out the oil passage in the push rod with bracket, with accessories at the front of the
compressed air. Check the ends of the push rods cylinder head. Install the oil level dipstick and oil
for nicks, grooves, roughness or excessive wear. level indicator tube assembly and speed control
Visually check the push rods for straightness or bracket, if so equipped.
check push rod runout with a dial indicator. Refer 9. Clean the valve cover gasket surfaces. Place the
to Section 03-00. If runout exceeds the maximum new gaskets on the valve covers. Make sure the
limit at any point, discard the push rod. tabs of the gasket engage the notches in the
5. lubricate the end of the push rods with valve cover. Install the valve covers.
Multi-Purpose Grease DOAZ-19584-AA or 10. Install the upper and lower intake manifolds and
equivalent meeting Ford specification related parts as outlined in this section.
ESB-M 1C93-A and install them in their original
positions. Apply Multi-Purpose Grease 11. Install the secondary air injection manifold tube at
DOAZ-19584-AA meeting Ford specification the rear of the cylinder heads. Reconnect the air
ESR-M 1C 159-A or equivalent to the valve stem supply hose to the secondary air injection pump
tips. (F-150), unplug the check valve and connect the
secondary air injection air supply hose.
6. lubricate the rocker arms and rocker arm seats
(6A528) with Multi-Purpose Grease
specification ESB-M 1C93-A, then install the
rocker arms.

ALL RIGHTS RESERVED
03-01B-26 Engines, 5.0L MFI V-8, 5.8L MFI V-8 and 5.8L MFI Lightning V-8 03-01B·2E
Crankshaft Pulley and/ or Damper and/or

Crankshaft Front Seal
CRANKSHAFT SEAL
SPECIAL SERVICE TOOL(S) REQUIRED REPLACER COVER ALIGNER

T86T-6701-A I
T70P-6B070-B
Front Cover Seal Installer / Cover Aligner T88T-6701-A
(0
Removal
1. Remove the serpentine drive belt.
(8146) to the radiator (8005).
3. Remove the fan clutch bolts from the water pump
shaft. Remove the fan blade (8600), fan clutch
(8A616) and fan shroud.
4. Remove the crankshaft pulley (6312) from the A10352·D
crankshaft vibration damper (6316). Remove the
damper attaching screw and washer. Install the
puller on the crankshaft vibration damper and
remove the crankshaft vibration damper.
5. Place the Front Cover Seal Remover 3. Apply Multi-Purpose Grease DOAZ-19584-AA or
T70P-6B070-B onto the engine front cover equivalent meeting Ford specification
(6019) over the crankshaft front seal (6700) as ESB-M 1C93-A to the oil seal rubbing surface of
shown. Tighten the two through-bolts to force the the vibration damper inner hub to prevent damage
seal puller under the seal flange. to the crankshaft front seal and to the front of the
6. Tighten the four puller bolts alternately one-half crankshaft for crankshaft vibration damper
turn at a time to pull the crankshaft front seal from installation.
the engine front cover. 4. Line up the crankshaft vibration damper keyway
with the key on the crankshaft. Install the
crankshaft vibration damper on the crankshaft.
Install the capscrew and washer. Tighten the
screw to 95-122 N·m (70-90 Ib-ft). Install the
crankshaft. Make sure the crankshaft pulley is
bottomed on the damper pilot.
5. Position the fan shroud over the water pump
pulley (8509). Install the fan blade and fan clutch.
Install the fan shroud attaching screws.
FRONT COVER
6. Route the drive belt according to the belt routing
________ SEAL REMOVER
decal.
- - - - - .. . .- - TOOL NO.
T70P-6B070·B
A5766-18
Water Pump
Installation
1. Coat a new crankshaft front seal with Lubriplate Removal
or equivalent. Place it onto Front Cover Seal 1. Drain the cooling system. Refer to Section 03-03.
Replacer /Cover Aligner T88T-6701-A. Place the 2. Remove drive belt.
sleeve and crankshaft front seal onto the end of
the crankshaft (6303) and push it toward the 3. Loosen the bolts on the fan clutch (8A616).
engine (6007) until the crankshaft front seal 4. Remove the bolts securing the fan shroud (8146)
starts into the engine front cover. to the radiator (8005). Position the fan shroud
2. Place the installation screw, washer and nut onto over the fan blade (8600).
the end of the crankshaft. Thread the screw into 5. Disconnect the lower radiator hose (8286),
the crankshaft. Tighten the nut against the heater water hose (18472) and water bypass
washer and installation sleeve to force the tube or hose (8548) at the water pump (8501).
crankshaft front seal into the engine front cover. Remove the fan blade, fan clutch and water pump
Remove the installation tool from the crankshaft. pulley (8509). Remove the fan shroud.
6. Remove water pump attaching bolts and remove
water pump from engine (6007).

ALL RIGHTS RESERVED
Installation CRANKSHAFT
1. NOTE: Before a water pump is installed, check it DAMPER
REMOVER
for damage. If it is damaged, replace it. D80L-522-A
Remove all gasket material from the mounting
surfaces of the engine front cover (6019) and
water pump.
2. Position a new gasket, coated on both sides with
Ford Perfect Seal Sealing Compound
B5A-19554-A or equivalent meeting Ford
specification ESE-M4G 1155-A, on the engine
front cover; then install the water pump. DAMPER REMOVAL - F-8ERIES
AND BRONCO A10375-E
3. Install the attaching bolts. lighten bolts to
20-28 N·m (15-21 Ib-ft).
3. Remove the oil pan-to-engine front cover
4. Position fan shroud over the water pump. attaching bolts. Use a thin-bladed knife to cut the
5. Install fan clutch to the fan blade and tighten bolts oil pan gasket flush with the cylinder block face
to 16-24 N·m (12-18Ib-ft). prior to separating the engine front cover from the
6. Position water pump pulley on hub and position cylinder block (6010). Remove the engine front
the fan blade and fan clutch assembly to the cover and water pump as an assembly.
water pump pulley. Install and tighten bolts to 4. Discard the engine front cover gasket.
16-24 N·m (12-18Ib-ft).
Installation
7. Install the fan shroud, lower radiator hose, heater
water hose aod water bypass tube or hose. 1. Clean the engine front cover, and the cylinder
lighten clamps to 3-4 N·m (27-35Ib-in). block gasket surfaces. Clean the oil pan gasket
surface where the oil pan (6675) and engine front
8. Install the drive belt. cover fasten.
9. Fill and bleed the cooling system. Refer to Install a new crankshaft front seal (6700) as
Section 03-03. Operate the engine until normal described in this section.
operating temperatures have been reached and
check for leaks. 2. Lubricate the timing chain/belt (6268) and
sprockets with heavy engine oil.
3. Coat the gasket surface of the oil pan with sealer,
then cut and position the required new gasket on
Engine Front Cover the oil pan and apply sealer at the corners. Install
the pan seal as required. Coat the gasket
SPECIAL SERVICE TOOL{S) REQUIRED
surfaces of the cylinder block and engine front
cover with Ford Perfect Seal Sealing Compound
Description Tool Number B5A-19554-A or equivalent meeting Ford
Front Cover Aligner Tool T61 P-60 19-B
specification ESE-M4G 115-A, and position a new
gasket on the cylinder block.
Damper Remover / Replacer Tool T79T-6316-A
4. Position the engine front cover on the cylinder
Removal block. Use care when installing the engine front
cover to avoid crankshaft front seal damage or
1. Refer to Water Pump Removal in this section.
possible gasket mislocation.
Perform all steps except removal of the water
pump (8501). Leave it attached to the engine
front cover (6019).
2. Remove the crankshaft pulley (6312) from the
damper attaching bolt and washer. Install Damper
Remover D80L-522-A or equivalent on the
crankshaft vibration damper and remove the
crankshaft vibration damper.

ALL RIGHTS RESERVED
5. Install the engine front cover using Front Cover

CRANKSHAFT
Aligner Tool T61P-6019-B. DAMPER REMOVERJREPLACER - - - -
TooL-T79T-6316-A
_ _ _~ A10171-18
10. Complete the remaining steps under Water Pump

Al7IO-1A Installation.
6. It may be necessary to force the engine front 11. Fill and bleed the cooling system. Refer to
cover downward to slightly compress the pan Section 03-03.
gasket. This operation can be facilitated by using 12. Operate the engine (6007) at fast idle and check
a suitable tool at the engine front cover attaching the coolant level and check for oil leaks. Check
hole locations. and adjust the ignition timing to specifications on
7. Coat the threads of the attaching screws with engine decal.
Ford Perfect Seal Sealing Compound 13. Install the engine air cleaner (ACL)(9600) and air
B5A-19554-A or equivalent meeting Ford cleaner outlet tube (9B659), including the
specification ESE-M4G 115-A and install the crankcase ventilation tube (6758).
screws. While pushing in on the alignment tool,
tighten the oil pan-to-cover attaching screws to
16-24 N·m (12-18Ib-ft). lighten the engine
cover-to-cylinder block attaching screws to
20-28 N·m (15-21 Ib-ft). Remove the alignment Timing Chains, Sprockets, Tensioner and
tool. Guides
8. Apply Multi-Purpose Grease DOAZ-19584-AA or Removal
ESB-M 1C93-A to the oil seal rubbing surface of 1. Check the timing chain / belt (6268) deflection.
the vibration damper inner hub to prevent damage Refer to Section 03-00. If deflection exceeds
to the crankshaft front seal and to the front of the specifications (12. 7mm [0.50 inch]), replace the
crankshaft (6303) for crankshaft vibration chain and sprockets.
damper installation. 2. Crank the engine (6007) until the timing marks on
9. Line up the crankshaft vibration damper keyway the sprockets are positioned as shown.
with the key on the crankshaft. Install the 3. Remove the camshaft sprocket capscrew,
crankshaft vibration damper on the crankshaft washers and fuel pump eccentric. Slide both
using Damper Remover / Replacer Tool sprockets and the timing chain / belt forward, and
T79T-6316-A. Install the capscrew and washer. remove them as an assembly.
lighten the screw to 95-122 N·m (70-90 Ib-ft).
Install the crankshaft pulley.

ALL RIGHTS RESERVED
03-018-29 Engines, S.Ol MFI v-a, s.al MFI v-a and S.al MFI lightning v-a 03·018-29
Installation 5.8LEnglne
1. Position the sprockets and timing chain / belt on
the camshaft (6250). Be sure the timing marks on
the sprockets are positioned as shown.
A10378-B
2. Install the fuel pump eccentric or timing flag,

washers and camshaft sprocket capscrew.
Tighten the sprocket capscrew to 54-61 N·m
(40-45 Ib-ft).
3. Lubricate the timing chain / belt and sprockets
with heavy engine oil.
A17898-B

ALL RIGHTS RESERVED
Camshaft
Part
Removal Item Number Description
1. Drain the cooling system. Disconnect the lower 9 6278 Camshaft Sprocket Washer
radiator hose (8286) and upper radiator hose 10 43002 Bolt
(8260). Disconnect the transmission oil cooler 11 6278 Flatwasher
lines, if so equipped. Remove the radiator (8005).
12 N605771-S Bolt
2. Remove the air conditioner and power steering Installation
bracket and accessories.
1. Oil the camshaft journals and apply Multi-Purpose
3. Remove the engine front cover (6019) and the Grease DOAZ-19584-AA or equivalent meeting
timing chain / belt (6268) following the procedure Ford specification ESB-M 1C93-A or equivalent to
under Engine Front Cover and Timing Chain, the lobes. Carefully slide the camshaft through
Removal, in this section. the bearings. Lubricate the camshaft thrust plate
4. Remove the intake manifold and throttle body with recommended quality engine oil and install
(9E926) as an assembly. the camshaft thrust plate with the groove toward
the cylinder block (6010).
5. Remove the valve tappets (6500) following the
procedure given under Disassembly and 2. Lubricate the valve tappets and valve tappet
Assembly in this section. bores with heavy engine oil. Install the valve
tappets in the bores from which they were
6. CAUTION: Use caution to avoid damaging removed.
the camshaft bearings.
3. Lubricate the ends of the push rods with
Remove the camshaft thrust plate (6269). Multi-Purpose Grease DOAZ-19584-AA or
Carefully remove the camshaft (6250) by pulling equivalent meeting Ford specification
toward the front of the engine (6007). ESB-M1C93-A and install the push rods (6565) in
their original positions. Apply Multi-Purpose
Grease DOAZ-19584-AA or equivalent meeting
Ford specification ESB-M 1C93-A to the valve
stem tips. Lubricate the rocker arms (6564) and
rocker arm seats (6A528) with Multi-Purpose
Grease DOAZ-19584-AA or equivalent meeting
Ford specification ESB-M 1C93-A and position
the rocker arms over the push rods. Tighten bolts
to 24-34 N·m (18-25Ib-ft).
4. Install the intake manifold and related parts as
5. Replace the crankshaft front seal (6700). Install
the timing chain, engine front cover and related
parts as described in this section.
6. Perform a valve clearance check as outlined.
7. Install the valve cover (6582) as described in this
section.
8. Clean and install the crankcase ventilation
system.
9. Install the radiator and connect the hoses. Refer
A10380-E to Section 03-03. Connect the oil transmission
cooler lines, if so equipped.
Part 10. Install air conditioner and power steering bracket
Item Number Description and accessories. Refer to Section 12-03A for air
conditioner service and Section 11-00 for power
1 6269 Thrust Plate steering service.
2 6261 Camshaft Bearings
Cover Section 03-03. Fill the crankcase with the proper
grade and quality of engine oil.
4 6250 Camshaft
5 6268 Timing Chain 12. Start the engine, then check and adjust the
6 6256 Camshaft Sprocket ignition timing (refer to the engine decal for
7 6287 5.8l Fuel Pump Outer correct settings). Connect the distributor and
Eccentric intake manifold vacuum hoses.
8 6A295 Inner Eccentric
(Continued)
1995 F·150, F·250, F·350, Bronco, F·Super Duty Powertrain, Drivetrain July 1994
ALL RIGHTS RESERVED
13. Operate the engine at fast idle and check all hose 10. Remove nuts and front lifting eye.
connections and gaskets for leaks. Operate the 11. Remove nuts and spark plug heat shield.
engine until engine temperatures have stabilized,
then adjust the engine idle speed and idle fuel 12. Remove studs and bolts, left exhaust manifold,
mixture (refer to specifications on engine decal). and gasket.
Retighten intake manifold bolts and nuts to 31-34
N·m (23-25 Ib-ft). Exhaust Manifold, 5.0l and 5.8l (5.8l Shown, 5.0l
Similar)
14. Install the engine air cleaner (ACl)(9600) and air
cleaner outlet tube (98659), including the
crankcase ventilation tube (6758).
Exhaust Manifolds
Removal
1. Raise vehicle.
2. Remove exhaust manifold-to-exhaust pipe nuts.
3. lower vehicle.
4. For right hand exhaust manifold (9430), remove \
engine air cleaner (ACl)(9600) assembly and air
cleaner outlet tube (9B659).
5. Remove nuts and upper intake manifold support
bracket, transmission dipstick tube bracket,
engine oil dipstick tube bracket, and wire
bracket.
6. loosen tube nut securing EGR tube to exhaust
manifold fitting. Disconnect EGR valve connector. A1581D-C
Remove two nuts and wire bracket. Remove two
studs, EGR external pressure valve (9F483) and
EGR valve to exhaust manifold tube (90477) as Part
an assembly, and gasket (5.8l only). Item Number Description
7. Remove nuts and spark plug heat shield 1 388496 Stud
(12A406). 2 9430 Exhaust Manifold (Right)
8. NOTE: Exhaust manifold studs/bolts vary by 3 381732 Bolt
length and type both by location on the particular 4 12A087 Spark Plug Heat Shield
vehicle and by model. Keep track of what 5 383745 Nut (2 Req'd)
studs/bolts go in what holes. A - Tighten to 24·32 N·m
(18-24 Lb-Ft)
NOTE: Bolt and stud location on 5.8l lightning
are the same as 5.0l / S.8l. B - Tighten to 16-23 N·m
(12·17 Lb-Ft)
Remove studs and bolts, right hand exhaust
manifold, and gasket.
9. For left exhaust manifold, remove secondary air
injection manifold tube (9B449) on vehicles with
C6 transmission.
ALL RIGHTS RESERVED
S.Ol and S.al Front lifting Eye 3. Install new gasket, left exhaust manifold, studs,
and bolts. Working from center to ends, tighten to
24-32 N·m (18-24Ib-ft).
4. Install spark plug heat shield and nuts. Torque
heat shield nuts to 16-23 N·m (12-17Ib-ft).
5. Install front lifting eye and nuts. lighten to
16-23 N·m (12-17 Ib-ft).
6. Install gasket, right exhaust manifold, studs, and
bolts. Working from center to ends, tighten to
24-32 N·m (18-24Ib-ft).
Exhaust Manifold, S.Ol and S.al (S.al Shown, S.Ol

Similar)
LIFTING EYE,
FRONT-17A084 A1S814-B
\
EXHAUST
..
MANIFOLD
STUDS
A1581~
FRONT OF
ENGINE
Part
1 388496 Stud
2 9430 Exhaust Manifold (Right)
3 381732 Bolt
4 12A087 Spark Plug Heat Shield
5 383745 Nut (2)
(18-24 Lb-Ft)
3/8-16 NUT
HEX FLANGE B - Tighten to 16-23 N·m
TORQUE TO (12-17 Lb-Ft)
(2) PLACES
24-32 N·m 7. Install spark plug heat shield and tighten nuts to
(18-24 FT-LB)
A17898·A 16-23 N·m (12-17 Ib-ft).
8. Inspect EGR valve to exhaust manifold tube and
Installation replace if rusted through or damaged. Install EGR
1. Clean mating surfaces of the exhaust manifold(s) valve to exhaust manifold tube loosely to manifold
and cylinder head (6049). Clean the exhaust pipe fitting. Install new gasket and valve to upper
spherical seat on the manifold(s) and the exhaust intake manifold. Tighten EGR valve studs to
pipe(s) sealing area. 18-26 N·m (13-19 Ib-ft). Tighten tube-to-exhaust
manifold fitting nut to 60-61 N·m (44-45 Ib-ft).
2. Inspect exhaust manifold(s) for cracks and
damaged gasket surfaces. Use a straightedge to 9. Install wire bracket, transmission dipstick tube
check for warped exhaust manifold cylinder head bracket, and upper intake manifold support
port branches. Replace unserviceable bracket. Tighten nuts to 16-24 N·m (12-18Ib-ft).
manifold(s).
ALL RIGHTS RESERVED
10. On models with C6 transmission, install 5. Position oil pan and oil pan flange reinforcement
secondary air injection manifold tube. Tighten (6A674) in place. Install and alternately tighten all
tube nuts to 23-34 N·m (17-25 Ib-ft). bolts (except for the four nearest the crankshaft)
11. Install engine air cleaner assembly and air intake to 9-14 N·m (80-123Ib-in). Tighten four remaining
tube. bolts to 16-24 N·m (12-18Ib-ft). Refer to the
following illustration.
12. Raise vehicle and install new exhaust
pipe-to-manifold gasket(s) and exhaust pipe(s).
Tighten flange nuts to 24-32 N·m (18-24Ib-ft).
13. Lower vehicle, operate and check for leaks.
Oil Pan and Oil Pump Screen Cover and Tube

Removal
(8146) to the radiator (8005) and position the fan
shroud over the fan assembly.
2. Remove the upper intake manifold (9424) as
3. Remove the nuts and lockwashers attaching the
engine support insulators to the chassis bracket.
4. Disconnect the oil cooler line at the left side of the
radiator if equipped with an automatic
transmission (7003).
5. Remove exhaust system. Refer to Section 09-00.
6. Raise the engine (6007) and place wood blocks
securely under the engine supports.
7. Drain the crankcase.
8. Support transmission with jack stand and remove
transmission crossmember. ~
FRONT OF ENGINE A
9. Remove the oil pan attaching boltb, and lower the
oil pan (6675) onto the crossmember.
10. Remove the two bolts attaching the oil pump
screen cover and tube (6622) to the oil pump
(6600). Remove nut attaching oil pump screen
cover and tube to the number 3 main bearing cap
stud. Lower the oil pump screen cover and tube
into the oil pan.
11. Remove the oil pan from the vehicle.
Installation A13396-F
1. Clean oil pan, oil pump screen cover and tube and
gasket surfaces. Inspect the gasket sealing Part
surface for damage and distortion due to Item Number Description
overtightening of the bolts. Repair and straighten 1 390657 Bolt, 5/ 16-18 x 1.12
as required. 2 6730 Oil Pan Drain Plug
2. Position a new oil pan gasket to the cylinder block 3 390658 Bolt, 1/4-20 x .94
(6010). 4 6A674 Reinforcement Oil Pan
3. Position the oil pump screen cover and tube to the Flange
oil pump, and install the lower attaching bolt and 5 6675 Oil Pan Assembly
gasket loosely. Install nut attaching oil pump 6 6710 Gasket, Oil Pan
screen cover and tube to number 3 main bearing A - Apply Silicone Rubber
cap stud and torque to 30-43 N·m (22-32 Ib-ft). D6AZ-19562-BA
(ESE-M4G92-A) Sealer
4. Install the upper pickup tube bolts. Tighten the (2 Places)
pickup tube bolts to 14-20 N·m (10-15 Ib-ft). B - Tighten to 20-33 N·m
(16-25 Lb-Ft)
(Continued)

ALL RIGHTS RESERVED
Part
FRONT OF ENGINE
C
0
-
-
(12-18 Lb-Ft)
(84-124 Lb-Ft)
•
6. Install the transmission crossmember and remove
jack stand.
7. Raise the engine and remove the wood blocks.
8. Lower the engine and install the
insulator-to-chassis bracket nuts and washers.
Tighten the nuts to 73-100 N·m (54-74Ib-ft).
9. Install the exhaust system. Refer to Section
09-00.
10. If equipped with an automatic transmission,
connect the oil cooler line at the radiator. Tighten
to 24-31 N·m (18-23 Ib-ft).
11. Install the upper intake manifold as described in
this section.
12. Install the fan shroud attaching bolts. Tighten to
7-10 N·m (62-89Ib-in).
13. Fill the crankcase with the proper grade and
quantity of engine oil. Install the oil level dipstick
A13397-e
(6750). Start the engine and operate it until it
reaches normal operating temperature, then
check for leaks. Part
1 33771 Nut,3/8-16
2 391378 Screw and Washer, 51 16-18
Oil Pump x 1.13
3 6625 Gasket
Removal 4 6600 Oil Pump
1. Remove the oil pan (6675) and related parts as 5 6A618 Oil Pump Intermediate Shaft
outlined. 6 6622 Oil Pump Screen and Cover
2. Remove the oil pump screen cover and tube Assembly (Typical)
(6622). 7 - Third Main (Reference Part
of 6010)
3. Remove the oil pump attaching bolts and oil pump 2041,8-S
8 Bolt
intermediate shaft (6A618).
(22-32 Lb-Ft)
(12-18 Lb-Ft)
Installation
1. Prime the oil pump (6600) by filling the inlet port
with engine oil. Rotate the oil pump intermediate
shaft to distribute the oil within the pump body.
2. Position the oil pump intermediate shaft into the
distributor socket. With the oil pump intermediate
shaft firmly seated in the distributor socket, the
stop on the oil pump intermediate shaft should
touch the roof of the crankcase. Remove the oil
pump intermediate shaft and position the stop as
necessary.
ALL RIGHTS RESERVED
3. NOTE: Do not attempt to force the oil pump into

position if it will not seat readily. The oil pump
intermediate shaft may be misaligned with the
distributor shaft. To align, rotate the oil pump
intermediate shaft into a new position.
With the stop properly positioned, insert the oil
pump intermediate shaft into the oil pump. Install
the oil pump and oil pump intermediate shaft as an
assembly. lighten the oil pump attaching screws
to 30-43 N·m (22-32 Ib-ft).
4. Clean the oil pump screen cover and tube.
Position assembly in place with a new gasket.
Install attaching bolts and tighten to 16-22 N·m
( 12-16Ib-ft).
5. Install the oil pan and related parts as outlined. CRANKSHAFT
JOURNAL A10363·B
Installation
Crankshaft Main Bearings 1. To install an upper crankshaft main bearing, place
The main bearing inserts are selective fit. Refer to the the plain end of the crankshaft main bearing over
procedures under Main and Connecting Rod the shaft on the locking tang side of the block and
Bearings-Fitting in Section 03-00. partially install the crankshaft main bearing so
that Main Bearing Insert Tool TOOL-6331-E can
Removal be inserted in the oil hole in the crankshaft. With
1. Drain the crankcase. Remove the oil level Main Bearing Insert Tool TOOL-6331-E in the hole
dipstick (6750). Remove the oil pan (6675)and in the crankshaft, rotate the crankshaft in the
related parts following the procedure under Oil opposite direction of engine rotation until the
Pan Removal. crankshaft main bearing seats itself. Remove the
tool.
2. Remove the oil pump screen cover and tube
(6622) and the oil pump (6600). 2. Install the bearing cap.
3. Replace one crankshaft main bearing (6333) at a 3. Select-fit the bearing for proper clearance
time, leaving the other crankshaft main bearings following the procedures under Main and
securely fastened. Remove the main bearing cap Connecting Rod Bearings-Fitting in Section
to which new crankshaft main bearings are to be 03-00.
installed. 4. If the crankshaft main bearing is being replaced
4. Insert Main Bearing Insert Tool TOOL-6331-E in on journal number 1, 2 or 4, apply a coat of
the oil hole in the crankshaft (6303). Motorcraft XO-1 OW30-GSP or DSP engine oil or
5. Rotate the crankshaft in the direction of engine ESE-M2C 153-E to the journal and crankshaft
rotation to force the crankshaft main bearing out main bearings and install the bearing cap. lighten
of the cylinder block (6010) . the cap bolts. On 5.0L engines (6007), tighten
6. Clean each crankshaft journal. Inspect the cap bolts to 82-95 N·m (60-70 Ib-ft); on 5.8L
journals and thrust faces (thrust bearing) for engines, tighten to 129-142 N·m (95-105Ib-ft).
nicks, burrs or bearing pickup that would cause
premature crankshaft main bearing wear.
7. If the rear crankshaft main bearing is being
replaced, remove and discard the crankshaft
rear oil seal (6701) as described in this section.
ALL RIGHTS RESERVED
5. NOTE: Join components within 15 minutes of

applying specified bead size of silicone rubber. Part
Before replacing rear main cap apply a 1.58mm
(1/16 inch) diameter bead of D6AZ-19562-A (or 3 - Leave 3. 10mm (1 /8 In.) Gap
B) sealer in shaded area of cylinder block as for Sealer Expansion
shown. 4 - 1.58mm (1 / 16 In.) Dia. Bead
D6AZ-19562-A (or B) Sealer
6 - From Forward Face of
Slinger Groove to Rear Face
of Block
7 6333 Rear Crankshaft Main
Bearing Cap
6. lubricate the journal with Motorcraft XO-1 OW30

GSP or DSP engine oil or equivalent meeting Ford
specification ESE-M2C 153-E and install the rear
main bearing cap. Tighten the cap bolts on 5.0l
engines to 82-95 N·m (60-70 Ib-ft); on 5.8l
engines to 129-142 N·m (95-105Ib-ft).
7. If the thrust bearing cap (No.3 main bearing) has
been removed, install it as follows:
SEALER APPUCAnON SKETCH lubricate the journal with Motorcraft
SPLIT LIP TYPE SEAL SHOWN XO-10W30-QSP or DSP ending oil or equivalent
BASIC APPLICAnON AREAS FOR meeting Ford specification ESE-M2C 153-E
OTHER SEAL INSTALLATIONS engine oil and install the thrust bearing cap with
ARE THE SAME
the bolts finger-tight. Pry the crankshaft forward
against the thrust surface of the upper half of the
thrust bearing. Hold the crankshaft cap to the
rear. This will align the thrust surfaces of both
halves of the crankshaft thrust main bearing
(6337). Retain the forward pressure on the
crankshaft. Tighten the cap bolts on 5.0l engines
to 82-95 N·m
(60-70 Ib-ft); on 5.8l engines to 129-142 N·m
(95-105Ib-ft).
8. Install a new crankshaft rear oil seal as described
in this section.
9. Force crankshaft toward the rear of the engine.
10. Check crankshaft end play. Refer to Section
A3724-J 03-00.
Part
1 - Apply 1.58mm (1. 16 In.) Dis.
Bead of D6AZ-19562-A
(or E) Sealer As Indicated on
Bearing Cap (Both Sides)
2 - Seal Groove
(Continued)
ALL RIGHTS RESERVED
PRY CRANKSHAFT FORWARD PRY CAP BACKWARD TlGffllN CAP
A10384-8
11. Clean the oil pump screen cover and tube. Prime 3. Make sure all connecting rod caps are marked so
the oil pump by filling the inlet opening with oil and that they can be installed in their original
rotating the oil pump intermediate shaft (6A618) positions.
until oil emerges from the outlet opening. Install 4. Turn the crankshaft until the connecting rod being
the oil pump and oil pump screen cover and tube. removed is down.
12. Position the oil pan gaskets on the oil pan. Install 5. Remove the connecting rod nuts and cap.
the oil pan and related parts following the
procedure under Oil Pan Installation. Install the oil 6. Push the connecting rod and piston assembly out
level dipstick. the top of the cylinder with the handle end of a
hammer. Avoid damage to the crankshaft journal
13. Fill the crankcase with the proper grade and or the cylinder wall when removing the piston and ~
quality of engine oil. Start the engine and check rod assembly.
for oil pressure. Operate the engine at fast idle
and check for oil leaks. 7. Remove the bearing inserts from the connecting
rod and caps.
8. Install the cap on the connecting rod from which it
was removed.
Pistons and Connecting Rods Installation
Removal 1. If new piston rings are to be installed, remove the
1. Drain the cooling system. Refer to Section 03-03. cylinder wall glaze. Refer to Section 03-00. The
Drain the crankcase. Remove the intake manifold small depression on the ring designates the top.
(9424), cylinder heads (6049), oil pan (6675) 2. Install rings using a piston ring installation tool of
and oil pump (6600) as outlined. the proper size.
2. Remove any ridges and / or deposits from the
upper end of the cylinder bores as follows.
Turn the crankshaft (6303) until the piston (6108)
to be removed is at the bottom of its travel, then
place a cloth on the piston head to collect the
cuttings. Remove the cylinder ridge with a ridge
cutter. Follow the instructions furnished by the
tool manufacturers. Never cut into the ring travel
area in excess of O. 794mm (1 /32 inch) when
removing ridges.
ALL RIGHTS RESERVED
3. NOTE: Be sure to install the pistons in the same

cylinders from which they were fitted.
Oil the piston rings, pistons and cylinder walls
with recommended quality engine oil. The
connecting rod and bearing caps are numbered
from 1 to 4 in the right bank and from 5 to 8 in the
left bank, beginning at the front of the engine
(6007). The numbers on the connecting rod and
bearing cap must be on the same side when
installed in the cylinder bore. If a connecting rod is
ever transferred from one cylinder block (6010)
or cylinder to another, new connecting rod
bearings (6211) should be fitted and the
connecting rod should be numbered to
correspond with the new cylinder number.
When installing the piston and connecting
rod assembly, the largest chamfer at the NOTCH TO' FRONT ..
bearing end of the rod should be positioned OF ENGINE •
toward the crank pin thrust face of the
crankshaft. 6. Check the clearance of each connecting rod
bearing. Refer to Main and Connecting Rod
4. Make sure the ring gaps (oil ring spacer-A, oil Bearings-Fitting in Section 03-00.
ring-B, compression ring-C) are properly spaced
around the circumference of the piston. 7. After the connecting rod bearings have been
fitted, apply a light coat of recommended engine
oil to the journals and connecting rod bearings.
8. Turn the crankshaft throw to the bottom of its
stroke. Push the piston all the way down until the
connecting rod bearing seats on the crankshaft
journal.
9. Install the connecting rod cap. Tighten the nuts on
5.0l engines to 26-33 N·m (19-24 Ib-ft); on 5.8l
engines to 54-61 N·m (40-45 Ib-ft).
10. After the piston and connecting rod assemblies
have been installed, use a feeler gauge to check
the side clearance between the connecting rods
on each shaft journal.
C
PISTON
6108
A2811·C
5. Install Piston Ring Compressor D81l-6002-C or
equivalent on the piston and push the piston in
with a hammer handle until it is slightly below the
top of the cylinder. Be sure to guide the
connecting rods to avoid damaging the
crankshaft journals. Install the piston with the
indentation notch in the piston head toward the
front of the engine.
11. Disassemble, clean, and assemble the oil pump.

Clean the oil pump screen cover and tube (6622)
and the oil pan and block gasket surfaces.
ALL RIGHTS RESERVED
12. Prime the oil pump by filling the inlet port with 2. Clean the crankshaft journal.
engine oil of the quality recommended in the 3. Install the bearing inserts in the connecting rod
Owner Guide and rotating the oil pump and cap with the tangs fitting in the slots
intermediate shaft (6A618) to distribute the oil provided.
within the housing. Install the oil pump and the oil
pan following the procedures under Oil Pan 4. Pull the connecting rod assembly down firmly on
Installation. the crankshaft journal.
13. Install the cylinder heads following the steps 5. Select fit the connecting rod bearing. Refer to
under Cylinder Head Installation. Main and Connecting Rod Bearings-Fitting in
Section 03-00.
14. Install accessory drive brackets with generator
(GEN)(10300), secondary air injection pump (AIR 6. Clean and apply a coat of Motorcraft
pump)(9A486), air conditioning compressor, and XO-10W30-QSP or DSP engine oil or equivalent
power steering pump (3A674) and connect hoses meeting Ford specification ESE-M2C 153-E to the
and electrical connections. journal and connecting rod bearings. Install the
connecting rod cap. Tighten the nuts on 5.0L
15. Install the intake manifold following the steps engines (6007) to 26-33 N·m (19-24Ib-ft); on
under Intake Manifold Installation. 5.8L engines to 54-61 N·m (40-45 Ib-ft).
16. Fill and bleed the cooling system. Refer to 7. Repeat the procedure for the remaining
Section 03-03. Fill the crankcase with the proper connecting rods that require new connecting rod
quality and quantity of engine oil as recommended bearings.
in the Owner Guide.
8. Clean the oil pump screen cover and tube. Prime
17. Start the engine, then check and adjust the the oil pump by filling the inlet opening with oil and
ignition timing. Connect the distributor vacuum rotating the oil pump intermediate shaft (6A618)
hoses to the distributor (12127). until oil emerges from the outlet opening. Install
18. Operate the engine at fast idle and check for oil the oil pump and oil pump screen cover and tube.
and coolant leaks. Operate the engine until engine 9. Position the oil pan gaskets on the cylinder block
temperatures have stabilized. (6010). Position the oil pan front seal on the
19. Install the engine air cleaner (ACL)(9600) and air engine front cover (6019) and interlock the seal
cleaner outlet tube (9B659) assembly, including with the gaskets. Position the oil pan rear seal on
the crankcase ventilation tube (6758). the rear main bearing cap and interlock the seal
with the gaskets. Install the oil pan and related
parts following the procedure under Oil Pan
Installation. Install the oil level dipstick.
Connecting Rod Bearings 10. Fill the crankcase with engine oil of the quality
The connecting rod bearings (6211) are selective fit. and quantity recommended in the Owner Guide.
Refer to Main and Connecting Rod Bearings-Fitting in Start the engine and check for oil pressure.
Section 03-00. Operate the engine at fast idle and check for oil
leaks.
Removal
1. Drain the crankcase. Remove the oil level
dipstick (6750). Remove the oil pan (6675) and
related parts, following the procedure under Oil Flywheel
Pan Removal.
Removal
(6622) and the oil pump (6600). 1. On a vehicle with a manual transmission (7003),
remove the transmission and flywheel housing,
3. Turn the crankshaft (6303) until the connecting clutch pressure plate (7563) and clutch disc
rod to which new connecting rod bearings are to (7550). Refer to Group 08.
be fitted is down.
On a vehicle with an automatic transmission,
Remove the connecting rod cap. Remove the remove the transmission and converter housing.
bearing inserts from the rod and cap. Refer to Group 07.
Installation 2. To check flywheel face runout or to replace a
1. Be sure the bearing inserts and the bearing bore flywheel ring gear for a manual transmission,
in the connecting rod and cap are clean. Foreign refer to Section 03-00.
material under the inserts will distort the
connecting rod bearing and cause a failure.
ALL RIGHTS RESERVED
3. Remove the flywheel attaching bolts and remove 2. On a vehicle with a manual transmission, check
the flywheel (6375). the flywheel runout. Refer to Section 03-00.
Install the clutch pressure plate, clutch disc and
the transmission and. flywheel housing. Refer to
Group 08.
On a vehicle with an automatic transmission,
check the flywheel runout. Refer to Section
03-00. Install the transmission and converter
housing. Refer to Group 07.
Crankshaft Rear Oil Seal

® Description Tool Number
2
Seal Replacer T82L-6701-A
Jet Plug Remover T77L-9533-B
Removal
1. Remove transmission (7003). If vehicle is
equipped with a manual transmission, remove
clutch assembly. Refer to either Group 07 or 08.
2. Remove flywheel (6375) from engine (6007).
3. CAUTION: Use caution to avoid scratching or
damaging the oil sealing surfaces during
crankshaft rear oil seal (6701) removal.
A13399-D
Using a sharp awl, punch one hole in the seal
metal surface between the seal lip and the
Part cylinder block (6010).
4. Screw the threaded portion of Jet Plug Remover
1 - Dowel (2 Places) T77L-9533-B into the hole and remove
(Part of 6007) crankshaft rear oil seal.
2 - Bolt (6 Places) Apply Pipe
Installation
Sealant with Teflon~
D8AZ-19554-A 1. Lubricate the crankshaft rear oil seal and seal
(ESG-M4G 194-A) to mating surfaces with clean engine oil.
Fasteners Prior to Assembly
(Part of 6375) 2. Position the new crankshaft rear oil seal on Rear
3 - Automatic Transmission Oil Seal Installer T82L-6701-A with the spring
Usage Identification side toward engine.
(Part of 6375)
3. NOTE: Bolts are supplied with installer tool.
4 6375 Flywheel Assembly Engine flywheel bolts may be substituted.
5 6A372 Rear Cover Assembly
A - Tighten to 102-115 N·m Position tool with crankshaft rear oil seal over the
(75-85 Lb-Ft) pilot diameter of the crankshaft (6303) and install
two bolts.
Installation ·4. Alternately tighten bolts until crankshaft rear oil
1. Coat the threads of the flywheel attaching bolts seal is properly seated to within o. 127mm (.005
with oil-resistant Threadlock and Sealer inch) of the rear face of the cylinder block.
EOAZ-19554-AA or equiva.lent meeting Ford 5. Install flywheel, clutch assembly (if equipped) and
specification ESE-M4G204-A5 (Type II). Position transmission. Refer to appropriate sections in
the flywheel on the crankshaft flange. Install and Groups 07 and 08.
tighten the bolts in sequence across from each
6. Check engine oil level and correct as required.
other to 102-115 N·m (75-85Ib-ft).
ALL RIGHTS RESERVED
7. Start engine and check for leaks. Oil Bypass Filter and Oil Filter Mounting
Insert
CYLINDER BLOCK Removal
~ 1. Position a drip pan under the oil bypass filter
FRONT OF ENGINE (6714)..
2. Unscrew the oil bypass filter from the oil cooler
mounting bolt insert (6L626) using an Oil Filter
Wrench D79L-6731-A or B or equivalent and
clean the oil cooler mounting bolt insert.
Unscrew the oil bypass filter from the oil cooler
mounting bolt insert, turn it horizontal and let the
excess oil drain off. Slide the oil bypass filter
toward the rear of the vehicle and remove. Some
effort may be required to slide the oil bypass filter
between the engine crossmember and power
steering hoses.
Installation
1. CAUTION: Make sure gasket from removed
SEAL
oil bypass filter has not stuck to the oil
cooler mounting bolt insert. Wipe oil cooler
mounting bolt insert clean prior to installing
A207.·A new oil bypass filter.
Coat the gasket on a new oil bypass filter with
recommended quality engine oil. Place the new oil
bypass filter in position on the oil cooler mounting
Camshaft Rear Bearing Cover bolt insert.
Removal 2. Hand-tighten the oil bypass filter until the gasket
makes contact and then advance it one-half turn.
1. On a vehicle with a manual transmission (7003)
move the transmission, flywheel housing, clutch 3. Check the oil level and fill the crankcase with
pressure plate (7563) and clutch disc (7550). engine oil of the quality recommended in the
Refer to Group 08. Owner Guide as necessary.
On a vehicle with an automatic transmission, 4. Operate the engine (6007) at fast idle and check
remove the transmission and converter housing. for oil leaks. If oil leaks are evident, perform the
Refer to Group 07. necessary repairs to correct the leakage.
Remove the drip pan.
2. Remove the flywheel attaching bolts and remove
the flywheel (6375). Remove the engine rear
plate (7007).
3. Replace the camshaft rear bearing cover (6266) Oil Filter Cooler and Oil Filter Mounting
as described in this section.
Insert, S.al lightning Truck Engine
Installation 1. Drain coolant. Refer to Section 03-03.
1. Coat the flywheel attaching bolts with 2. Raise vehicle and position a drain pan under the
oil-resistant Threadlock and Sealer engine (6007). Drain crankcase.
EOAZ-19554-AA or equivalent meeting Ford
specification ESE-M4G204-A5 (Type II). Position 3. Loosen hose clamps and remove hoses from oil
the engine rear plate on the cylinder block cooler (6A642) assembly.
dowels. Position the flywheel on the crankshaft 4. Remove oil bypass filter (6714) using suitable
flange. Install and tighten the attaching bolts in wrench.
sequence, across from each other to 102-115
5. Remove oil filter mounting insert (6890) from
N·m (75-85Ib-ft).
engine and separate oil cooler from oil filter
2. On a vehicle with a manual transmission, install mounting insert.
the clutch pressure plate, clutch disc,
For installation, follow removal steps in reverse order.
transmission, and the flywheel housing. Refer to
Install a new oil bypass filter. Fill crankcase with
Group 08.
proper quantity and grade of oil. Fill cooling system.
3. On a vehicle with an automatic transmission, Refer to Section 03-03. Start engine and check for
install the transmission and converter housing. leaks.
Refer to Group 07.
ALL RIGHTS RESERVED
VIEW A
FRONT OF ENGINE
A24060·A
Part Part
1 8501 Water Pump A - Tighten to 55-67 N·m
2 6010 Cylinder Block (40-50 Lb-Ft)
3 6A642 Oil Cooler B - Tighten 1/2 Turn After
Contact
4 6L626 Oil Cooler Mounting Bolt
Insert C - Tighten to 2.2-4.5 N·m
(20-40 Lb-In)
5 6714 Oil Filter
6 6K741 Oil Cooler Adapter
D - Position with Clamp Screws
Parallel to Face of Oil
7 - Clamp (Part of 6K741) Cooler, Tighten to 3.3-5.6
8 9H447 Clamp N·m (30-50 Lb-In)
(Continued)
NOTE: Lightly oil attaching bolt and stud threads

before installation, except those specifying special
sealant.
Refer to Section 03-00 for the cleaning and inspection
procedures.
ALL RIGHTS RESERVED
Oil Level Indicator Tube Installation

5.0LEngine 1. Install oil pressure sensor in cylinder block.
lighten to 16-24 N·m (12-18 Ib-ft).
Removal
2. Install oil cooler adapter to water pump (8501).
1. Drain the crankcase. Refer to Section 03-00. Tighten to 2-5 N·m (17-44Ib-in).
2. Remove the oil level dipstick (6750). 3. NOTE: ESE-M998144-A (Surfactant) may be
3. Remove nut from oil level indicator tube (6754) used to facilitate assembly of the oil cooler
bracket and remove oil level indicator tube. adapter assembly hoses to the water pump and
oil cooler assembly. The Surfactant concentration
Installation can be 10% maximum (10 parts water to 1 part
1. Apply a light film of WSE-M2C903-A2 oil to the Surfactant).
outer diameter of the end of the tube, prior to Install oil cooler and oil cooler mounting bolt insert
inserting the oil level indicator tube approximately to cylinder block. Tighten to 54-61 N·m (40-45
1/2 inch. Ib-ft).
2. Apply ESE-A2G348-A 15 (WSK-M2G349-A 10) 4. Install oil cooler adapter to oil cooler. Tighten to
sealer at oil level indicator tube joint. The oil level 2-5 N·m (17-44Ib-in).
indicator tube must be bottomed out in the
cylinder block (6010). 5. Prior to installation of oil bypass filter apply a light
film of WSE-M2C903-A 1 oil on the oil bypass
3. Install 3/8-16 nut on oil level indicator tube filter gasket.
bracket. Tighten nut to cylinder head (6049)
16-23 N·m (12-17 Ib-ft). 6. Install oil bypass filter. Turn 1/2 turn after gasket
contact. Optional torque to 11-14 N·m (97-124
4. Install oil level dipstick. Ib-in).

5.8LEngine
Removal Engine
1. Drain the crankcase. Refer to Section 03-00. The engine removal and installation procedures are for
2. Remove oil level dipstick (6750) from oil level the crankshaft front seal (6700) only, without the
indicator tube (6754). transmission attached.
3. Remove nut from oil level indicator tube bracket
and exhaust manifold (9430) stud. Remove oil
level indicator tube from cylinder block (6010). Description Tool Number
Installation Engine Lifting Bracket Tool T70p-eooo
1. Apply WSK-M2G349-A 10 sealer around the
periphery of the oil level indicator tube on the
Removal
cylinder block installation. 1. Drain the cooling system and the crankcase.
Refer to Section 03-03. Remove hood. Refer to
2. Insert loose fit oil level indicator tube into the
Section 01-02.
cylinder block with a rotational movement.
2. Disconnect the battery and ground cables from
3. Install 3/8-16 nut on oil level indicator tube
bracket to exhaust manifold stud. the cylinder block (6010).
4. Tighten nut to 16-24 N·m (12-18Ib-ft). 3. On 5.8l MFI engine, remove the air cleaner outlet
tube (98659) assembly, including the crankcase
5. Install oil level dipstick in oil level indicator tube. ventilation tube (6758) and evaporative emission
hose (9G297). On S.Ol MFI engine, remove the
air cleaner outlet tube, crankcase ventilation
tube, and evaporative emission hose.
Sensors 4. Disconnect the lower radiator hose (8286) and
Oil Pressure Sender/Switch upper radiator hose (8260) at the radiator
(8005). If equipped with an automatic
Removal transmission, disconnect the transmission oil
1. Remove oil bypass filter (6714), oil cooler cooler lines.
mounting bolt insert (6L626), oil cooler (6A642) 5. Disconnect and cap-off the power steering
and oil cooler adapter. hoses.
2. Remove oil pressure sensor (9278) from cylinder 6. Disconnect the secondary air injection manifold
block (6010). tubes (98449).
ALL RIGHTS RESERVED
7. Discharge the air conditioning system if so

equipped and remove the air conditioning
condenser. Refer to Section 12-03A. Disconnect
air conditioning lines at the compressor.
Disconnect the air conditioning compressor
clutch wire.
8. Remove the fan shroud (8146) and position it
..
over the fan. Remove the radiator. Refer to
Section 03-03. Relieve the belt tension and
remove the belt.
· ~;~J
9. Disconnect the generator wires.
10. Remove the brackets for the secondary air FRONT OF
injection pump (AIR pump)(9A486), generator, VEHICLE
power steering and compressor. Disconnect the VIEW SHOWING INSTAlLAnON OF
power steering pump lines. FRONT ENGINE MOUNTS FOR 6.0L AND S.8l
11. Disconnect the oil pressure sending unit wire from ENGINESF·150-F·350ANDBRONCO F
A4992·
the sending unit. Disconnect evaporative
emission hoses at the evaporative canister.
Part
12. Perform Fuel System Pre-Service Procedures,
Section 03-04A or 03-04D. Using Quick
Disconnect Tools D87L-9280-A and -B or 1 N800114-S2 Bolt
equivalent, disconnect fuel line and fuel return line. 2 N800937-S2 Nut
13. Disconnect accelerator cable, transmission valve 3 6028 Bracket
cable and, if equipped, speed control cable and 4 387811-S2 Bolt
remove cable bracket from throttle body 5 60037 Heat Shield
(9E926). Position bracket with attached cables 6 N802114-S2 Bolt
out of the way. Disconnect power brake booster 7 - Nut (Part of 60037)
vacuum hose, if so equipped. 8 388049-S2 Nut and Washer Assembly
14. Disconnect the heater hoses from the water A - Tighten to 58-77 N·m
pump (8501) and tee. Disconnect the engine (43-57 Lb-Ft)
coolant temperature sensor wire from the sending B - Tighten to 81-108 N·m
unit. (60-80 Lb-Ft)
15. Remove the flywheel housing-to-engine upper
(71-94 Lb-Ft)
bolts.
16. Disconnect the engine wire loom and position out 19. Remove the converter inspection plate. On
of the way. Disconnect the ground strap from the vehicles with automatic transmission (7003)
cylinder block. remove the torque converter-to-flywheel
attaching bolts.
17. Raise the front of the vehicle. Disconnect the
starter cable from the starter motor ( 11 00 1). 20. Remove the remaining flywheel housing-to-engine
Remove the starter motor. Refer to Section bolts.
03-06A. 21. Lower the vehicle, and support the transmission.
18. Disconnect the muffler inlet pipes and exhaust Install Engine Lifting Bracket Tool T70P-6000 on
heat control valve, if so equipped, from the the intake manifold lifting eyes (5.8L). Then,
exhaust manifolds. Disconnect the engine attach the engine lifting sling (attach to
support insulators from the brackets on the frame engine-mounted lifting eyes for 5.0L).
underbody. 22. Raise the engine (6007) slightly and carefully pull
it from the transmission. Carefully lift the engine
out of the engine compartment so that the engine
rear plate (7007) is not bent or other components
damaged. Install the engine on a workstand.
Installation
1. Attach the engine lifting brackets and sling.
Remove the engine from the workstand.
2. Lower the engine carefully into the engine
compartment. Make sure the dowels in the block
are through the engine rear plate, then engage
the holes in the flywheel housing.
ALL RIGHTS RESERVED
3. NOTE: If the engine hangs up after the shaft 20. Connect two air conditioning lines to the air
enters, turn the crankshaft slowly (transmission in conditioning compressor if so equipped. Refer to
gear) until the shaft splines mesh with the clutch Section 12-038.
disc splines. 21. Install the radiator. Connect the upper and lower
Start the transmission main driveshaft into the radiator hoses. Connect the transmission oil
clutch disc (7550). On a vehicle with manual cooler lines, if so equipped. Install the fan shroud.
transmission, it may be necessary to adjust the Refer to Section 03-03.
position of the transmission in relation to the 22. Install the air conditioning condenser to the
engine if the input shaft will not enter the clutch radiator if so equipped. Refer to Section 12-03A.
disc.
23. Connect the heater hoses at the water pump and
4. Install the flywheel housing upper bolts. Tighten to intake manifold (9424). Fill and bleed the cooling
68-88 N·m (50-65 Ib-tt). system. Refer to Section 03-03. Fill the
5. Install the engine support insulator-to-bracket crankcase with the proper grade and quantity of
washers and attaching nuts. Disconnect the oil. Connect the power brake booster vacuum
engine lifting sling and remove the lifting eyes hose, if so equipped.
(5.8L). 5.0L lifting eyes remain with engine. 24. Connect battery ground cable (14301).
6. Raise the front of the vehicle. Connect both 25. NOTE: When the battery has been disconnected
exhaust manifolds and exhaust heat control and reconnected, some abnormal drive
valve, if so equipped, to the muffler inlet pipes. symptoms may occur while the powertrain
lighten the nuts to 33-49 N·m (24-36 Ib-ft). Refer control module (PCM)( 12A650) relearns its
to Section 09-00. adaptive strategy. The vehicle may need to be
7. Position and install the starter motor and the driven 10 miles or more to relearn the strategy.
starter cable. Reter to Section 03-06A. Operate the engine at fast idle and check all
8. Install the remaining flywheel housing-to-engine gaskets and hose connections for leaks. Purge
bolts. lighten to 68-88 N·m (50-65 Ib-ft). the power steering system of any air as outlined
9. Install the converter-to-flywheel attaching bolts. in Section 11-00.
On a vehicle with automatic transmission, install 26. Install the engine air cleaner (ACL)(9600) and air
the converter inspection plate. cleaner outlet tube including the crankcase
10. Remove the support from the transmission and ventilation hose and carbon canister hose.
lower the vehicle. 27. Evacuate and charge the A / C system, if so
11. Install the air conditioner and power steering equipped. Refer to Section 12-03A.
bracket and components. Refer to Section 03-05. 28. Install hood. Refer to Section 01-02.
12. Install the generator / secondary air injection
pump bracket. Refer to Section 03-05.
13. Connect the air conditioning compressor
magnetic clutch lead wire if so equipped. Refer to
Camshaft Bearings
Section 12-038. Camshaft bearings (6261) are available prefinished to
size for standard and 0.38mm (0.015 inch) undersize
14. Connect the engine wire loom.
journal diameters. The camshaft bearings are not
15. Connect the engine coolant temperature sensor interchangeable from one bore to another.
wire.
16. Install bracket with attached cables to throttle SPECIAL SERVICE TOOL(S) REQUIRED
body. Connect accelerator, transmission valve, Description Tool Number
and automatic speed control cables.
Camshaft Bearing Set T65L-6250-A
17. Connect fuel supply and return lines. Connect
evaporative emission hoses. Connect oil Removal
pressure sending unit wire.
1. Remove the camshaft (6250), flywheel (6375)
18. Install the water pump pulley (8509), fan clutch and crankshaft (6303) as outlined. Push the
(8A616) and fan blade (8600). Position the fan pistons (6108) to the top of the cylinders.
shroud over the fan blade. lighten to 17-24 N·m
( 13-18Ib-ft). 2. Select the proper size expanding collet and
backup nut and assemble on the expanding
19. Position the generator (GEN)(10300) and install mandrel Camshaft Bearing Set T65L-6250-A.
the generator bolts. Connect the battery ground
cable. Install generator, secondary air injection 3. With the expanding collet collapsed, install the
pump, and power steering pump (3A674). Install collet assembly in the camshaft bearing, and
poly-V belt according to instructions on decal. tighten the backup nut on the expanding mandrel
Refer to Section 03-05. until the collet fits the camshaft bearing.
19~5 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain July 1994
ALL RIGHTS RESERVED
4. Assemble the puller screw and extension (if 5. Repeat the procedure for each camshaft bearing.
necessary) and install on the expanding mandrel. To remove the front bearing, install the puller
Wrap a cloth around the threads of the puller screw from the rear of the cylinder block (6010).
screw to protect the front bearing or journal.
Tighten the pulling nut against the thrust bearing
and pulling plate to remove the camshaft bearing.
Be sure to hold a wrench on the end of the puller
screw to prevent it from turning.
Camshaft Bearings
Part Part
1 - Pulling Screw 7 - Puller Screw Extension
2 - Pulling Plate 8 - Front Spacer
3 - Expanding Mandrel NOTE: All items Except No.6
(Bearing) Are Included in
4 - Expanding Collet Camshaft Bearing Set
5 - Backup Nut T65L-6250-A
6 - Bearing, Camshaft (Part
Number Given is for
Reference Only)
(Continued)
Installation
1. Position the new camshaft bearing at the bearing
bores with the oil holes aligned and press them in
place with the Camshaft Bearing Set
T65L-6250-A. Be sure to center the pulling plate
and puller screw to1ivoid damage to the
camshaft bearing. Failure to use the correct
expanding collet can cause severe camshaft
bearing damage. Make sure the front camshaft
bearing is installed 0.127-0.508mm
(0.005-0.020 inches) below the front face of the
cylinder block.
A10385-B
2. Install a new rear bearing bore plug.
1995 F-150, F-250, F-350, Bronco, F-Super Duty P·owertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
03-01B-47 Engines, 5.0l MFI v-a, 5.al MFI v-a and 5.al MFI lightning v-a 03-01B-47
Install the camshaft, crankshaft, flywheel and 9. NOTE: Handle the crankshaft with care to avoid
related parts as outlined. Do not check possible fracture or damage to the finished
connecting rod and main bearing clearances as a surfaces.
part of Camshaft Bearing Replacement. Install the Carefully lift the crankshaft out of the cylinder
engine (6007) in the vehicle. block (6010) so that the thrust bearing surfaces
are not damaged.
10. Remove rear journal oil seal from the crankshaft.
Crankshaft 11. Remove the main bearing inserts from the
cylinder block and bearing caps.
SPECIAL SERVICE TOOL(S) REQUIRED 12. Remove the connecting rod bearing (6211) from
Description Tool Number the connecting rods and caps.
Damper Remover / Replacer Tool T79T-6316-A
To refinish journals and dress minor
imperfections, refer to Section 03-00.
Installation
Removal
1. If the crankshaft main bearing journals have been
1. With the engine (6007) removed from the vehicle refinished to a definite undersize, install the
and placed in a workstand, disconnect the correct undersize crankshaft main bearings
distributor to spark plug wires (12286) at the (6333).
spark plugs (12405) and remove the wires and
bracket assembly from the attaching stud on the
2. CAUTION: Be sure the bearing inserts and
valve covers (6582) using Spark Plug Wire
bearing bores are clean. Foreign material
Remover T74P-6666-A. Disconnect the ignition
under the inserts will distort the crankshaft
coil to distributor high tension wiring (12298) at
main bearing and cause a failure.
the ignition coil (12029). Remove the distributor Place the upper crankshaft main bearing inserts
cap (12106) and distributor to spark plug wires in position in bores with the tang fitting in the slot
as an assembly. Remove the spark plugs to allow provided.
easy rotation of the crankshaft (6303). 3. Install the lower crankshaft main bearing inserts
2. Remove the oil bypass filter (6714). Slide the in the bearing caps.
water pump bypass hose clamp toward the water 4. NOTE: Be careful not to damage the bearing
pump (8501). Remove the generator surfaces.
(GEN)( 10300) and mounting brackets.
Carefully lower the crankshaft into place.
crankshaft vibration damper (6316). Remove the 5. Check the clearance of each crankshaft main
capscrew and washer from the end of the bearing. Refer to Main and Connecting Rod
crankshaft. Install the Crankshaft Damper Bearings-Fitting in Section 03-00.
Remover Replacer T79T-6316-A on the 6. Apply engine oil of the quality recommended in
crankshaft vibration damper and remove the the Owner Guide to the journals and crankshaft
crankshaft vibration damper. main bearings.
4. Remove the engine front cover (6019) and water 7. NOTE: Apply Silicone Rubber D6AZ-19562-B
pump as an assembly. meeting Ford specification ESB-M4G92-A in a
5. Check the timing chain deflection. Then, remove 1.59mm (1 / 16-inch) bead in each corner of rear
the timing chain / belt (6268) and sprockets by main bearing cap saddle, the full length of the
following procedure under Engine Front Cover saddle.
and Timing Chain Removal. NOTE: Be sure that the main bearing caps are
6. Invert the engine on the workstand. Remove the installed in their original locations.
clutch pressure plate (7563) and clutch disc Install all the crankshaft main bearing caps,
(7550) (manual shift transmission). Remove the except the thrust bearing cap (No.3 bearing).
flywheel (6375) and engine rear plate (7007). Tighten the bearing cap bolts on 5.0L engines to
Remove the oil pan (6675) and gasket. Remove 82-95 N·m (60-70 Ib-ft); on 5.8L MFI engines to
the oil pump (6600). 129-142 N·m (95-105Ib-ft).
7. NOTE: Make sure all bearing caps (main and 8. Install the thrust bearing cap with the bolts
connecting rod) are marked so that they can be finger-tight.
installed in their original locations.
9. Pry the crankshaft forward against the thrust
Turn the crankshaft until the connecting rod from surface on the upper half of the crankshaft main
which the cap is being removed is down, and bearing.
remove the bearing cap. Push the connecting rod
and piston assembly up into the cylinder. Repeat 10. Hold the crankshaft forward and pry the thrust
bearing cap to the rear. This will align the thrust
this procedure until all the connecting rod bearing
caps are removed. surfaces of both halves of the crankshaft thrust
main bearing (6337).
8. Remove the main bearing caps.
ALL RIGHTS RESERVED
REMOVAL AND INSTALLATION (Continued) DISASSEMBLY AND ASSEMBLY
~ 11. Retain the forward pressure on the crankshaft.

lighten the cap bolts on 5.0l engines to 82-95
Cylinder Block
N·m (60-70 Ib-ft); on 5.8l engines to 129-142 SPECIAL SERVICE TOOL(S) REQUIRED
N·m (95-105Ib-ft).
12. Force the crankshaft toward the rear of the
engine. Cylinder Ridge Reamer T64L-60 11-EA
13. Check the crankshaft end play. Refer to Section Disassembly

03-00.
1. NOTE: Before starting disassembly, remove all
14. Install new bearing inserts in the connecting rods wiring harnesses, emission control system, fuel
and caps. Check the clearance of each bearing. system, ignition system, flywheel (6375), engine
Refer to Main and Connecting Rod rear plate (7007) and components front end
Bearings-Fitting in Section 03-00. accessory drive components.
15. Apply a light coat of recommended quality engine
oil to the journals and connecting rod bearings For more detailed information on a particular system,
after the connecting rod bearings have been refer to the specific section in the appropriate repair
fitted. group.
16. Turn the crankshaft throw to the bottom of its NOTE: All valve train components should be identified
stroke. Push the piston (6108) all the way down to make sure they are installed in their original
until the connecting rod bearing seats on the positions during assembly.
crankshaft journal. With the engine (6007) mounted on a workstand:
17. Install the connecting rod cap. lighten the nuts on Remove the left and right valve covers (6582) and
5.0l engines to 26-33 N·m (19-24Ib-ft); on 5.8l discard the gaskets.
to 54-61 N·m (40-45 Ib-ft). 2. Remove the upper and lower intake manifold
18. Using a feeler gauge to check the side clearance (9424) assemblies.
between the connecting rods on each connecting 3. Remove the oil level dipstick (6750) and oil level
rod crankshaft journal after the piston and indicator tube (6754) assembly and remove the
connecting rod assemblies have been installed. oil bypass filter (6714).
Refer to Specifications at the end of this section.
4. Remove the rocker arms (6564), rocker arm
19. Install a new crankshaft rear oil seal (6701) as seats (6A528), push rods (6565), rocker arm
described in this section. fulcrum guides (6A588) and valve tappets (6500)
20. Install the timing chain / belt, the sprockets, and remove the cylinder heads (6049) as
engine front cover and crankshaft pulley and outlined.
adapter as outlined.
21. Coat the threads of the flywheel attaching bolts
with oil-resistant Threadlock and Sealer
specification ESE-M4G204-A5 (Type II). Position
the flywheel on the crankshaft flange. Install and
tighten the bolts to 102-115 N·m (75-85Ib-ft).
On a flywheel for manual shift transmission
(7003), use Clutch Housing Alignment Tool
T75l-6392-A to locate the clutch disc. Install the
clutch pressure plate. lighten the attaching bolts
to 27-39 N·m (20-29Ib-ft).
22. Clean the oil pan, oil pump and oil pump screen
cover and tube (6622). Prime the oil pump by
filling the inlet port with engine oil and rotating the
oil pump intermediate shaft (6A618) to distribute
oil within the housing. Install the oil pump and oil A487O-C
pan as described in this section.
23. Install the oil bypass filter. Part
24. Install the spark plugs, distributor cap and Item Number Description
1 390385 Attaching Bolt
distributor high tension wiring. 2 8A528 Rocker Arm Seat
3 6564 Rocker Arm
25. Install the engine in the vehicle as described in 4 6A588 Rocker Arm Fulcrum Guide
this section.
5 6049 Threaded Pedestal (Part of
Cylinder Head)
ALL RIGHTS RESERVED
5. Remove the crankshaft pulley (6312) and 11. Remove the camshaft thrust plate (6269) and
crankshaft vibration damper (6316) as outlined. remove the camshaft (6250).
6. Remove the water pump (8501) and engine front 12. NOTE: Pistons (6108), connecting rods and
cover (6019) as an assembly. Discard the gasket bearings should be numbered to make sure they
and seal. are assembled in their original positions.
7. Remove the oil pan (6675) and discard the NOTE: Before removing pistons inspect the top of
gasket. the cylinder bores. If necessary, remove the ridge
8. Remove the oil pump (6600), oil pump screen and / or carbon deposits from each cylinder using
cover and tube (6622) assembly and oil pump Cylinder Ridge Reamer T64L-6011-EA.
intermediate shaft (6A618) . Remove the connecting rod caps and remove the
piston.
•
FRONT OF ENGINE
A13397-e
Part
13. CAUTION: When removing the crankshaft
Item Number Description (6303), take care not to damage any of the
1 33771 Nut,3/8-16 bearing surfaces on the crankshaft.
2 391378 Screw and Washer, 5/ 16-18 NOTE: The location of the main bearing caps and
x 1.13
the main bearing inserts should be identified.
3 6625 Gasket When the engine is assembled, crankshaft main
4 6600 Oil Pump bearings (6333) which are to be reused should be
5 6A618 Oil Pump Intermediate Shaft installed in their original positions.
6 6622 Oil Pump Screen Cover and
Tube (Typical)
Remove the crankshaft main bearing caps,
crankshaft main bearings and crankshaft.
7 - Third Main (Part of 6010)
8 20418-S Bolt 14. For cleaning purposes, the oil gallery and coolant
A - Tighten to 30-43 N·m drain plugs can be removed.
(22-32 Lb-Ft)
(12-18 Lb-Ft)
9. Remove the crankshaft rear oil seal (6701).

10. Remove the camshaft sprocket, capscrew,
washer and eccentric or timing flag. Slide the
sprocket and timing chain / belt (6268) forward
and remove the timing chain / belt and sprocket as
an assembly.

ALL RIGHTS RESERVED
03-018-50 Engines, 5.0L MFI V-8, 5.8L MFI V-8 and 5.8L MFI Lightning V-8 03-01B-50
Crankshaft, Disassembled View
A10383-C
Part Part
1 6333 Crankshaft Main Bearing 8 6306 Crankshaft Sprocket
2 7120 Clutch Pilot Bearing 9 - Bolt (Part of 6303)
3 6375 Flywheel 10 6378 Washer
4 6701 Crankshaft Rear Oil Seal 11 388813 Bolt
5 6333 Crankshaft Main Bearing 12 6312 Pulley
6 6325 Main Bearing Caps 13 1616/6A329 Damper
(Part of 6A338) 14 372890-S Key
7 384664 Bolt 15 6303 Crankshaft
(Continued)
Assembly 2. Install the lower crankshaft main bearings in the

Before assembling cylinder block (6010), all sealing bearing caps.
surfaces must be clean and free of chips, dirt, paint, 3. Carefully lower crankshaft into place. Use care to
and foreign material. Also make sure coolant and oil prevent damage to bearing surfaces.
passages are clear. .1
4. Check clearance of each crankshaft main
If new piston rings are to be installed and no visible bearing, following the procedure under Main and
cross hatch marks remain on the cylinder wall, remove Connecting Rod Bearings-Fitting in Section
cylinder wall glaze using a spring-type tool. Follow 03-00.
instructions of tool manufacturer. 5. Apply a light coat of engine oil to the journals and
1. NOTE: Lightly oil all attaching bolt and stud crankshaft main bearings after crankshaft main
threads before installation, except those bearings have been fitted.
specifying special sealant. 6. NOTE: Make sure main bearing caps are installed
Place crankshaft upper main bearings in position in their original positions.
in the bores with the tang fitting in the slot Install all bearings and caps except thrust bearing
provided. Lubricate bearings with SAE 50 weight cap (No.3 bearing). Refer to Main Bearings,
oil meeting Ford specification ESE-M2C39-F or Installation in this section for installation of thrust
equivalent. bearing cap. Tighten bearing caps to
specification.
ALL RIGHTS RESERVED
03-018-51 Engines, 5.0l MFI V-8, 5.8l MFI V-8 and 5.8l MFI Lightning V-8 03-018-51
7. Install crankshaft rear oil seal as described in this

section. Install engine rear plate and flywheel and
tighten bolts to specification.
®
2
..
FRONT OF ENGINE
BOLT
12-16 N-m
(9-12 FT-LB)
(2 PLACES)
A134OO-B
10. Check camshaft end play. Refer to Section

03-00. If not within specification, replace
camshaft thrust plate.
11. Install camshaft sprocket (6256) and timing
chain / belt. Position camshaft sprocket and
timing chain / belt on camshaft and crankshaft
sprocket simultaneously. Make sure timing marks
A13399-D on the sprockets are aligned.
Part
1 - Dowel (2 Places)
2 - Bolt, 7/16-20 x .72
(6 Places) Apply Pipe
Sealant with Teflon~
D8AZ-19554-A
(ESG-M4G 194-A) to
Fasteners Prior to Assembly
3 - Automatic Transmission
Usage Identification
4 6375 Flywheel Assembly
5 6A372 Rear Cover Assembly
(75-85 Lb-Ft)
8. Coat all camshaft bearings (6261), camshaft

lobes and camshaft sprocket spacer (6265) with
engine oil.
9. Carefully slide camshaft through camshaft
bearings. Install camshaft thrust plates with
groove toward cylinder block. lighten thrust plate
retaining bolts. lighten to 12-16 N·m (9-12 Ib-ft).
12. Install eccentric or timing flag, washers, and

camshaft capscrew. lighten camshaft capscrew
to 54-61 N·m (40-45 Ib-ft).

ALL RIGHTS RESERVED
13. Oil the piston rings, pistons and cylinder walls. Be

sure to install the pistons in the same cylinders
from which they were removed.
14. Make sure the ring gaps are properly spaced
around the circumference of the piston. (Refer to
Pistons and Connecting Rods Installation in this
section.)
15. NOTE: Install piston with indentation notch in the
piston head toward front of engine.
Install a piston ring compressor on the piston and
push piston in with a hammer handle or an
appropriate piston hammer until it is slightly below
top of cylinder. Be sure to guide connecting rods
to avoid damaging crankshaft journals (cover
studs).
21. Prime the oil pump and install oil pump, oil pump
intermediate shaft, and oil pump screen cover and
tube assembly. Tighten oil pump bolts to 30-43
N·m (22-32 Ib-ft).
..
FRONT OF ENGINE
16. Check clearance of each connecting rod bearing

(6211). Refer to procedure in Section 03-00.
17. After connecting rod bearings have been fitted,
apply a light coat of engine oil to the crankshaft
connecting rod journals and connecting rod
bearings.
18. Turn the crankshaft throw to the bottom of its
stroke. Push piston all the way down until
connecting rod bearing seats on the crankshaft
journal.
19. Install connecting rod cap. Install nuts and tighten
to 26-33 N·m (19-24Ib-ft) for 5.0l engines, or to
54-61 N·m (40-45 Ib-ft) for 5.8l engines.
20. Check side clearance between connecting rods A13397-C
on each crankshaft journal after piston and
connecting rod assemblies have been installed. Part
1 33771 Nut, 3/8-16
2 391378 Screw and Washer, 5/ 16-18
x 1.13
3 6625 Gasket
4 6600 Oil Pump
5 6A618 Oil Pump Intermediate Shaft
6 6622 Oil Pump Screen Cover and
Tube (Typical)
(Continued)
ALL RIGHTS RESERVED
03-018-53 Engines, 5.0l MFI V-8, 5.8l MFI V-8 and 5.8l MFI lightning v-a 03-018-53
Part
7 - Third Main (Part of 6010)
8 20418-S 80lt
(22-32 Lb-Ft)
(12-18 Lb-Ft)
22. Install crankshaft front seal (6700) in engine front

cover. (Refer to the procedure in this section.)
23. Install crankshaft front seal, gasket, timing
pointer (6023) and engine front cover. lighten
cover bolts to specification. Refer to Procedure in
this section. Also, install crankshaft vibration
damper and crankshaft pulley and torque bolt to
specification.
24. Install new oil bypass filter.
25. Install oil pan gasket and seal assembly. Install oil
pan. lighten oil pan bolts to specification. lighten
the four 5/ 16-18 x 1.12 oil pan bolts to 16-24
N·m (12-18Ib-ft) and the remaining 1/4-20 x .94
oil pan bolts to 9-14 N·m (80-124Ib-in).
~
FRONT OF ENGINE A
()
VIEW A
A13396-F
Part
1 390657 801t, 5/ 16-18 x 1. 12
3 390658 801t, 1/4-20 x .94
4 6A674 Reinforcement Oil Pan
Flange
5 6675 Oil Pan Assembly
6 6710 Gasket, Oil Pan
A - Apply Silicone Rubber
D6AZ-19562-8A
(ESE-M4G92-A) Sealer
(2 Places)
(16-25 Lb-Ft)
(12-18 Lb-Ft)
(84-124 Lb-Ft)
26. Install valve tappets in their original bores.

ALL RIGHTS RESERVED

'.
27. Install tappet guide plate (roller tappet engines 32. Install lower and upper intake manifolds. Use
only) and tighten screws and washers to guide pins to ease installation of intake manifolds
specification. onto cylinder heads.
28. NOTE: If cylinder heads were completely 33. Tighten intake manifold bolts in two steps using
disassembled, refer to Cylinder Head the sequence shown.
Disassembly and Assembly procedures in this Step 1 - 16 N·m (12Ib-ft)
section.
Step 2 - 31-34 N·m (23-25 Ib-ft)
Position head gaskets (6051) on cylinder block.
Install cylinder head locating dowels. Install
cylinder heads.
S.Ol and S.al Shown, S.al lightning Similar
29. Tighten cylinder head bolts to specification, in the
sequence shown.
A1 0374-1 A
30. Install push rods, rocker arms, rocker arm seats,

rocker arm fulcrum guides, and tighten fulcrum
bolts to 24-34 N·m (18-25Ib-ft).
31. NOTE: This sealer sets up within 15 minutes after
application. To assure effective sealing,
assembly should proceed promptly. A10198-e
Apply 1.6mm (1 / 16-inch) bead of Silicone
Rubber D6AZ-19562-BA or equivalent meeting 34. Install oil level indicator tube and oil level dipstick
Ford specification ESB-M4G92-A sealer to the assembly.
end seals (junction). 35. Position valve cover gasket (6584) in each valve
cover and install valve covers.
Refer to Valve Cover and Rocker Arm, Installation
in this section.
36. Install wiring harnesses, emission control system,
fuel system, ignition system and front end
accessory drive components, by referring to
'procedure in appropriate section.
SUBASSEMBLIES'
Cylinder Head
A371~N SPECIAL SERVICE TOOL(S) REQUIRED
Part
I De8c~ption I Tool Number I
Item Number Description I Valve Spring Compressor I T70P-6049-A I
1 - Sealer (4-Joints) Disassembly
1. Remove the exhaust manifolds and the spark
3 9439 Intake Manifold Gasket
plugs (12405).
4 9A424/9A425 Intake Manifold Seal
5 - Sealer (4-Seal Ends) 2. Clean the carbon out of the cylinder head
6 6010 Cylinder Block combustion chambers before removing the
valves.

ALL RIGHTS RESERVED
3. Carefully compress the valve spring (6513) using

Valve Spring Compressor T70P-6049-A. Remove
the valve spring retainer key (6518) and release
the valve spring.
4. Remove the sleeve, spring retainer or

retainer / rotator, valve spring, guide mounted
stem seal and valve. Discard the valve stem seal
(6571). Identify all valve parts.
5. Clean, inspect and repair the cylinder head FRONT OF ENGINE
(6049) as required, or transfer all usable parts to
a new cylinder head.
A17841·A
Part
1 6518 Key
2 6A516 Retainer / Rotator
(Exhaust Only)
3 6517 Sleeve (Intake Only)
4 6514 Retainer (Intake Only)
5 6513 Spring, Valve
6 6A517 Seal, Valve
(White, Intake Only)
7 6507 Valve, Intake
8 6505 Valve, Exhaust
10 6A517 Seal, Valve (Exhaust Only)
Assembly
1. Install each valve in the port from which it was
removed or to which it was fitted. Install a new
valve stem seal on the intake valve guide and
exhaust valve guide.
2. Install the valve spring over the valve, and then
install the spring retainer and sleeve. Compress
the valve spring using Valve Spring Compressor
T70P-6049-A and install the valve spring retainer
keys.

ALL RIGHTS RESERVED
3. CAUTION: Do not install the spacers unless Piston Pin, Removal and Installation
necessary. Use of spacers In excess of
recommendations will result In overstressing
the valve springs and over,loadlng the
camshaft lobes which could lead to valve
spring breakage and worn camshaft lobes.
Measure the assembled height of the valve spring
from the surface of the cylinder head spring pad
to the underside of the spring retainer with
dividers. Check the dividers against a scale. The
spring assembled heights should measure 1.78
inch for intake and 1.60 inch for exhaust. If the
assembled height is greater than specifications,
install the necessary 0.762mm (0.030-inch) thick
spacer(s) between the cylinder head spring pad . INSERT TAPERED PILOT
and the appropriate valve spring to bring the 2 IN PISTON PIN FOR
assembled height to the recommended height. PIN REMOVAL
INSERT THIS END
IN PISTON HOLE
FOR INSTALLATION
SURFACE OF
SPRING PAD A10087·1 A
4. Install the exhaust manifolds and the spark plug.

REMOVAL INSTALLAnON
Pistons, Piston Pins and Rings A4871-F
Part
De8crlptlon Tool Number Item Number Description
Piston Pin Remover / Replacer T68P-6135-A 1 - Driver (Part of T68P·6135-A)
2 - Locator
Disassembly (Part of T68P-6135-A)
1. Remove the bearing inserts from the connecting 3 - Adapter
rod and cap.
2. Mark the pistons (6108) to make sure they are
4 - Cup (Part of T68P-6135-A)
assembled with the same rod and installed in the

5 - Pin Pusher
same cylinders from which they were removed. 6 6135 Piston Pin
3. Using an arbor press and the Piston Pin 7 - Receiving Tube
Remover / Replacer T68P-6135-A, press the (Part of T68P-6135-A)
piston pin from the piston and connecting rod.
Remove the piston rings if they are to be Assembly
replaced. The piston, connecting rod and related parts are
shown. Check the fit of a new piston in the cylinder
bore before assembling the piston and piston pin to the
connecting rod.
The piston pin bore of a connecting rod and the
diameter of the piston pin must be within specifications
in this section.

ALL RIGHTS RESERVED
1. NOTE: Assemble the piston to the connecting rod

with the indentation in the piston positioned as
shown.
Apply a light coat of recommended quality engine
oil to all parts.
On replacement connecting rods, install the
large-chamfered side of the connecting rod
bearing bore toward the crankshaft cheek; facing
toward front of engine (6007) on the right bank
rods, and facing toward rear of engine on left
bank rods.
RIGHT BANK LEFT BANK
FRONT OF
ENGINE
•
A8672·1B
A10370-B
Part
1 6148 Ring Set-Piston (Upper)
2 - Ring Set-Piston (Lower)
(Part of 6148)
3 - Oil Ring (Part of 6148)
4 6110 Piston
5 6211 Bearing Connecting Rod
6 6210 Cap - Main Bearing
7 6212 Nut
8 6214 Bolt
9 6200 Rod Assembly -
Connecting
10 6135/6108 Piston Pin
2. Start the piston pin in the piston and connecting

rod (this may require a very light tap with a
mallet). Using an arbor press and Piston Pin
Remover / Replacer T68P-6135-A, press the
piston pin through the piston and connecting rod
until the pin is centered in the piston.
3. Check the end gap of all piston rings. Refer to
Section 03-00. It must be within specifications.
Follow the instructions contained on the piston
ring package and install the piston rings using a
piston ring installation tool of the proper size.

ALL RIGHTS RESERVED
4. NOTE: If the lower lands have high steps, the

piston should be replaced. Part
Check the ring side clearance of the compression
rings with a feeler gauge inserted between the 3 6670 Oil Pump Relief Valve Spring
ring and its lower land. Refer to Section 03-00. 4 6614 Oil Pump Relief Valve Repair
The gauge should slide freely around the entire Kit
ring circumference without binding. Any wear that 5 6600 Body Assembly
occurs will form a step at the inner portion of the 6 - Bolt (Part of 6600)
lower land. 7 - Identification Mark
5. Make sure the bearing inserts and the bearing 8 - Bolt (Part of 6600)
bore in the connecting rod and cap are clean. 9 6616 Plate
Foreign material under the inserts will distort the 10 6608 Rotor and Shaft Assembly
connecting rod bearing (6211) and cause a 11 6626 Gasket
failure. Install the connecting rod bearing inserts 12 6622 Oil Pump Screen Cover and
in the connecting rod and cap with the tangs Tube
fitting in the slots provided. A - Tighten to 14-20 N·m
(10-15 Lb-Ft)
Oil Pump
Disassembly (22-32 Lb-Ft)
Assembly
(6622) from the oil pump (6600) and remove the
gaskets. 1. Clean, inspect and oil all parts thoroughly.
2. Remove the cover attaching bolts, then remove 2. Install the oil pressure relief valve plunger, spring
the cover. Remove the inner rotor and shaft and a new cap.
assembly. Then remove the outer race. 3. NOTE: Be sure the dimple (identification mark) on
3. Drill a small hole and insert a self-threading sheet the outer race is facing the same side as the
metal screw of the proper diameter into the oil identification mark on the rotor.
pressure relief valve chamber cap and pull the Install the outer race and the inner rotor and shaft
cap out of the chamber. Remove the spring and assembly.
plunger.
4. Install the cover and tighten the cover attaching
bolts to 30-43 N·m (22-32 Ib-ft).
Valve Tappet, Hydraulic
The Internal parts of each hydraulic tappet
assembly are matched sets. Do not mix the parts.
Keep the assemblies intact until they are to be
cleaned.
Valve tappets (6500) should always be tested after
assembly. Refer to Section 03-00.
Disassembly
Disassemble and assemble each valve tappet
separately. Keep the valve tappets in proper
sequence so that they can be installed in their original
bores.
1. Grasp the plunger retainer with needlenose pliers
to release it from the groove. It may be necessary
to depress the leakdown plunger to fully release
the plunger retainer.
2. Remove the push rod socket, metering valve
(disc), plunger and spring.
A2535-F 3. Carefully remove the plunger spring, the check
valve retainer socket, the check valve spring and
Part valve from the plunger.
2 6A616 Oil Pump Relief Valve Plug
(Continued)

ALL RIGHTS RESERVED
Roller Tappet, 5.0L/5.8L Engines

Part
3 - Leakdown Plunger
(Part of 6500)
4 - Push Rod Socket
(Part of 6500)
5 - Plunger Retainer
(Part of 6500)
6 - Body (Part of 6500)
Assembly
1. Place the plunger upside down on a clean
workbench.
2. Place the check valve (disc or check ball) in
position over the oil hole on the bottom of the
plunger. Set the check valve spring on top of the
A18238-A check valve (disc or check ball).
3. Position the check valve retainer over the check
Part valve and spring and push the retainer down into
Item Number Description place on the plunger.
1 - Cam Roller (Part of 6500) 4. Place the plunger spring, and then the plunger
2 - Needles (Part of 6500) (open end up) into the valve tappet body.
3 - Axle (Part of 6500) 5. Position the metering valve (disc) in the plunger
4 - Plunger Spring (Part of 6500) and then place the push rod socket in the plunger.
5 - Check Ball Spring 6. Depress the plunger, and position the closed end
(Part of 6500) of the plunger retainer in the groove of the valve
6 - Ball Retainer (Part of 6500) tappet body. With the plunger still depressed,
7 - Check Ball (Part of 6500) position the open ends of the plunger retainer in
8 - Leakdown Plunger the groove. Release the plunger, and then
(Part of 6500) depress it again to fully seat the plunger retainer.
9 - Plunger Retainer 7. Use the Tappet Leakdown Tester TOOL-6500-E
(Part of 6500)
to fill the valve tappets with test fluid. Refer to
10 - Plunger Retainer Section 03-00.
(Part of 6500)
11 - Body (Part of 6500) Cylinder Block Assembly
Disassembly
Non-Roller Tappets, 5.8L Lightning Engine
1. Mount the engine in a workstand and remove all
parts not furnished with the new cylinder block
(6010) assembly following engine components
removal and installation procedures in this
section.
2. Remove the cylinder block assembly from the
workstand.
Assembly
1. Clean the gasket and seal surfaces of all
serviceable parts and assemblies.
2. Position the new cylinder block assembly in a
workstand.
3. Transfer all serviceable parts removed from the
old cylinder block assembly following engine
components removal and installation procedures
Part in this section.
4. Check all assembly clearances following
1 - Check Ball Spring Specifications listed at the end of this section,
(Part of 6500) and correct as necessary.
2 - Check Ball (Part of 6500)
(Continued)

ALL RIGHTS RESERVED
Cylinder Block, Bare 2. Install an auxiliary starter switch between the

Before replacing a cylinder block, determine if it is battery and S terminal of the starter relay. Crank
repairable. If so, make the necessary repairs. Refer to the engine (6007) with the ignition switch in off
Section 03-00. position until the No.1 piston (6108) is on TDC
after the compression stroke.
Disassembly 3. Position the tappet compressor tool, Tappet
1. Completely disassemble the engine following Bleed Down Wrench T71 P-6513-B on the rocker
appropriate removal and installation procedures arm (6564) with the crankshaft (6303) in the
in this section. positions designated in Steps 4, 5 and 6.
2. Ridge-ream the cylinder bores before removing Slowly apply pressure to bleed down the valve
piston assemblies. tappet until the plunger is completely bottomed.
Hold the valve tappet in this position and check
Assembly
the available clearance between the rocker arm
1. Clean the gasket and seal surfaces of all and the valve stem tip with a feeler gauge.
serviceable parts and assemblies.
If the clearance is less than specifications, install
2. Position the new cylinder block in a workstand. a shorter push rod. If the clearance is greater
3. Transfer all serviceable parts removed from the than specifications, install a longer push rod.
old cylinder block following appropriate removal
and installation procedures in this section.
4. Check all assembly clearances. Refer to
Specifications and correct as necessary.
ADJUSTMENTS
Valve Clearance

Tappet Bleed Down Wrench T71 P-6513-B
The valve arrangement of the left bank is E-I-E-I-E-I-E-I

and on the right bank is I-E-I-E-I-E-I-E.
A 1.52mm (0.060 inch) shorter push rod (6565) or a
1.52mm (0.060 inch) longer push rod is available for
service to provide a means of compensating for
dimensional changes in the valve mechanism. Refer to
the Master Parts List for the appropriate color code.
Valve stem-to-valve rocker arm clearance should be
within specifications with the hydraulic valve tappet
(6500) completely collapsed. Repeated valve
reconditioning operations (valve and / or valve seat
refacing) will decrease the clearance to the point that
if it is not compensated for, the hydraulic valve tappet
will cease to function and the valve will be held open. 4. With the No. 1 piston on TDC at the end of the
compression stroke, POSITION 1, check the
The positive stop rocker arm bolts eliminate the following valves:
necessity to adjust the valve clearance. However, to
obtain the specified valve clearance, it is important No. 1 Intake NO.1 Exhaust
that all valve components be in a serviceable condition No. 7 Intake No.5 Exhaust
and installed and tightened properly.
No. 8 Intake No.4 Exhaust
To determine whether a shorter or a longer push rod is
5. Rotate the crankshaft to POSITION 2 and check
necessary, make the following check.
the following valves:
5.0L (302 CID) MFI v-a Engine No. 5 Intake No.2 Exhaust
1. Disconnect the brown lead (I terminal) and the red No. 4 Intake No.6 Exhaust
and blue lead (S terminal) at the starter relay.
6~ Rotate the crankshaft to POSITION 3 and check

ALL RIGHTS RESERVED
03-018"61 Engines, 5.0L MFI Y-8, 5.8L MFI Y-8 and 5.8L MFI Lightning Y-S 03-018-61
No. 6 Intake NO.8 Exhaust
WITH NO.1 AT TDC AT END OF COMPRESSION

STROKE MAKE A CHALK MARK AT POINTS 2 AND 3
APPROXIMATELY 90 DEGREES APART.
r~~~~(3)
POSITION 1 - NO.1 AT TDC AT END OF COMPRESSION

STROKE.
POSITION 2 - ROTATE THE CRANKSHAFT 180 DEGREES
(1/2 REVOLUTION) CLOCKWISE FROM
POSITION 1.
POSITION 2.
A3234-H
5.8L (351 CID) MFI W-Y-8 and 5.8L MFI

Lightning W-Y-8 Engines
1. Disconnect the red and blue leads (S terminal) at
the starter relay.
4. With the No. 1 piston on TDC at the end of the
2. Install an auxiliary starter switch between the compression stroke, POSITION 1, check the
battery and S terminals of the starter relay. Crank following valves:
the engine with the ignition switch in off position
until the No. 1 piston is on TDC on the No. 1 Intake No. 1 Exhaust
compression stroke. No.4 Intake No.3 Exhaust.
3. With the crankshaft in the positions designated in No. 8 Intake NO.7 Exhaust
steps 4, 5 and 6, position the tappet compressor
tool on the rocker arm. 5. Rotate the crankshaft to POSITION 2 and check
Slowly apply pressure to bleed down the valve
tappet until the plunger is completely bottomed. No. 3 Intake No.2 Exhaust
Hold the valve tappet in this position and check No. 7 Intake NO.6 Exhaust
the available clearance between the rocker arm 6. Rotate the crankshaft to POSITION 3 and check
and the valve stem tip with a feeler gauge. the following valves:
If the clearance is less than specifications, install No. 2 Intake No.4 Exhaust
a shorter push rod. If the clearance is greater
than specifications, install a longer push rod. No. 5 Intake No.5 Exhaust

ALL RIGHTS RESERVED
c
03-018-62 Engines, 5.0L MFI V-8, 5.8L MFI V-8 and 5.8L MFI Lightning V-8 03';'018-62
1 .
WITH NO.1 AT TDC AT END OF COMPRESSION

STROKE MAKE A CHALK MARK AT POINTS 2 AND 3
APPROXIMATELY 90 DEGREES APART.
~~~(13)
POSITION ,- -NO.1 AT TDC AT END OF COMPRESSION

STROKE.
POSITION 1.
POSITION 2.
A3234-H
SPECIFICATIONS
ENGINE SPECIFICATIONS
011 Pressure Hot @
2000 RPM
. Engine Type and
Engine Bore and Stroke Firing Order kPa (PSI) Num.ber of Cylinders
5.0l (302 CID) MFI V-8 4.00 x 3.00 13726548 275-413 (40-60,) O.H.V. V-8
6.8l (351 CII?) MFI W-Y-8 4.00 x 3.50 13726548 275-448 (40-65) O.H.V. V-8
5.8l (351 CID) MFI lightning W-V-8 4.00x 3.50 13726548 275-448 (40-65) O.H.V. V-8
General Specifications
CYLINDER HEAD AND VALVE TRAIN
Valve Guide Bore
Diameter Valve Seat Width-
Combustion
Chamber Valve Seat Valve Gasket
Volume RunoutTIR Arrangement Surface
Engine C.C. b Intake Exhaust Intake Exhaust Maximum Front to Rei" FlatnessC
.003 in Any
.3433- .3433- .060- .060- RT I-E-I-E-I-E-I-E
5.0l (302 CID) MFI V-8 60.6-63.6 .002 6 Inches
.3443 .3443 .080 .080 LT E-I-E-I-E-I-E-I
.006 Overall
.003 in Any
.3433- .3433- .060- .060- RT I-E-I-E-I-E-I-E
5.8l (351 CID) MFI W-V-8 60.6-63.6 .002 6 Inches
.3443 .3443 .080 .080 l T E-I-E-I-E-I-E-I
.006 Overall
.003 in Any ~
5.8l (351 CID) lightning .3433- .3433- .060- .060- RT I-E-I-E-I-E-I-E
60.6-63.6 .002 6 Inches
MFIW-V-e .3443 .3443 .oeo .oeo l T E-I-E-I-E-I-E-I
.006 Overall
b Compression pressure (psi) of the lowest cylinder must be at least 75 % of the highest to be within specification.
c Gasket surface finish - rms 60-150.
ALL RIGHTS RESERVED
03-018-63 Engines, 5.0l MFI v-a, 5.al MFI v-a and 5.al MFI Lightning v-a 03-018-63
VALVE ROCKER ARM SHAFT, PUSH RODS AND TAPPETS

Collapeed Tapped Gap
Valve Tappet· or Lifter (Clearance)
Hydraulic
Rocker Arm Push Rod Lifter
Lift Ratio RunoutTIR Standard Clearance Leakdown
Engine to 1 Maximum Diameter to Bore- Rateb Allowable Desired
10to 50
5.0L (302 elO) MFI V-8 1.59 .015 .8740-.8745 .0007-.0027 Seconds for .071-.171 .091-.151
1/16 Travel
10 to 50
5.8L (351 elO) MFI W-V-8 1.59 .015 .8740-.8745 .0007-.0027 Seconds for .071-.171 .091-.151
1/16 Travel
10to 50
5.8L (351 elO) MFI Lightning W-V-8 1.59 .015 .8740-.8745 .0007-.0027 Seconds for .092-.192 .112-.172
1/16 Travel
b Time required for plunger to leakdown .0625 inch under load of 50 Ibs. using leakdown fluid in tappet.
VALVE SPRINGS
Valve Spring Free
Valve Spring Compression Length
Pressure (lbs.) @ Specified Height (Approximate) Valve Spring Assembled Height
Valve
Spring
Out of
Engine Intake- Exhaust Intake Exhaust Intake Exhaust Square
5.0L (302 elC) MFI V-8 74-82@ 1.78 76-84@ 1.60 2.06 1.88 1.75-1.81 1.58-1.64 5/64
196-212@ 1.36 190-210@ 1.20 (.078)
5.8L (351 elO) MFI W-V-8 74-82@ 1.78 76-84@ 1.60 2.06 1.88 1.75-1.81 1.58-1.64 5/64
190-210@ 1.20 190-210@ 1.20 (.078)
5.8L (351 elO) MFI W-V-8 74-82@ 1.78 76-84 @ 1.60 2.06 1.88 1.75-1.81 1.58-1.64 5/64
Lightning 190-210@ 1.20 190-210@ 1.20 (.078)
a Service limit - 10% loss pressure.
VALVES
Valve Stem to Guide Clearance 8 Valve Head Dlameterb

Valve Face
Runout
Engine Intake Exhaust Intake Exhaust Maximum
5.0L (302 elO) MFI V-8 .0010-.0027 .0015-.0032 1.690-1.694 1.439-1.463 .002
5.8L (351 elO) MFI W-V-8 .0010-.0027 .0015-.0032 1.770-1.794 1.453-1.468 .002
5.8L (351 elO) MFI Lightning W-V-8 .0010-.0027 .0015-.0032 1.837-1.847 1.536-1.546 .002
a Service clearance - .0055.
b Valve face angle - 44 0 •
VALVE STEM DIAMETER

Engine Intake Exhaust Intake Exhaust Intake Exhaust
5.0L (302 elD) MFI
.3415-.3423 .3410-.3418 .3565-.3573 .3561-.3568 .3715-.3723 .3711-.3718
V-8
5.8L (351 elD) MFI
.3415-.3423 .3410-.3418 .3565-.3573 .3561-.3568 .3715-.3723 .3711-.3718
W-V-8
5.8L (351 elO) MFI
.3415-.3423 .3410-.3418 .3565-.3573 .3561-.3568 .3715-.3723 .3711-.3718
V-8

ALL RIGHTS RESERVED
03-018·64 Engines, 5.0L MFI V-8, 5.8L MFI V-8 and 5.8L MFI Lightning V-8 03-018-64
CAMSHAFT
Lobe Lift· Camshaft End Play
Camshaft Journal to
Engine Intake Exhaust End Play Wear Limit Bearing Clearance b
5.0l (302 CIC) MFI V-8 .2780 .2830 .001-.007 .009 .001-.003
5.8l (351 CIC) MFI .2780 .2830 .001-.007 .009 .001-.003
W-V-8
5.8l (351 CIC) MFI .2600 .2780 .001-.007 .009 .001-.003
lightning W-V-8
b Service limit - .006 maximum.
CAMSHAFT DRIVE
Camshaft Journal Diameter - Standard· Camshaft Bearing Inside Diameter
Camshaft
Front
Bearing
Engine No.1 No.2 No.3 No.4 No.5 No.1 No.2 No.3 No.4 No.5 Locatlon b
5.0l (302 CID) 2.0815 2.0655 2.0515 2.0365 2.0215 2.0835 2.0685 2.0535 2.0385 2.0235 .005-.020
MFIV-8
5.8l (351 CIC) 2.0815 2.0665 2.0515 2.0365 2.0215 2.0835 2.0685 2.0535 2.0385 2.0235 .005-.020
MFI W-V-8
5.8l (351 CIC) 2.0815 2.0665 2.0515 2.0365 2.0215 2.0835 2.0685 2.0535 2.0385 2.0235 .005-.020
MFI lightning
W-V-8
b Distance in inches that front edge of bearing is installed below the front face of the cylinder block.
NOTE: Timing chain deflection - .500 inch maximum.
CYLINDER BLOCK
Distributor Head Gasket
Cylinder Bore Main Bearing Shaft Bearing Surface Head Gasket Tappet Bore
Engine Diameter· Bore Dlameterb Bore Diameter Flatness Surface Finish Diameter
5.0l (302 CIC) MFI V-8 4.0004-4.0052 2.4412-2.4420 .4525-.4541 .003 in any 6 in. RMS .8752-.8767
.006 overall 60-150
5.8l (351 CID) MFI 4.0000-4.0048 3. 1922-3. 1930 .5155-.5170 .003 in any 6 in. RMS .8752-.8767
W-V-8 .006 overall 60-150
5.8l (351 CIC) MFI 4.0000-4.0048 3. 1922-3. 1930 .5155-.5170 .003 in any 6 in. RMS .8752-.8767
lightning W-V-8 .006 overall 60-150
a Maximum out-of-round - .0015, service limit - .005, maximum taper service limit - .010, cylinder bore surface finish - rms 18-38,
Bore tapes service limit - .010.
b Crankshaft to rear face of block run out. TIR maximum .005.

Main Bearing Main and
Main Bearing Main Bearing Journal Thrust Rod Bearing Main aearlng
Main Bearing Journal Thrust Face Taper Bearing Journal Thrust Face
Journal Runout TIR RunoutTIR Maximum Journal FlnlshRMS FlnlshRMS
Engine Diameter· Maxlmumb Maximum Per Inch Length Maximum Maximum
5.0l (302 CID) MFI V-8 2.2482- .002 .001 .0005 1. 137-1. 139 12 25 Front-
2.2490 20 Rear
5.0l (351 CIC) MFI 2.9994- .002 .001 .0005 1.137-1.139 12 25 Front-
W-V-8 3.0002 20 Rear
5.8l (351 CIC) MFI 2.9994 .002 .001 .0005 1.137-1.139 12 25 Front-
lightning W-V-8 -3.0002 20 Rear
1995 F-150, F-250, F-350, Bronco, F-Super Du~y Powertrain, Drivetrain July 1994
ALL RIGHTS RESERVED

Connecting Rod
Connecting Rod Journal Taper
Journal Per Inch Crankshaft Free Flywheel Clutch
Engine Assembled Dlameter8 Maximum End Playb Face Runout
5.0L (302 CID) MFI V-8 2. 1228-2. 1236 .0006 .004-.008 0.010
5.8L (351 CID) MFI W-V-8 2.3103-2.3111 .0006 .004-.008 0.010
5.8L (351 CID) MFI Lightning W-V-8 2.3103-2.3111 .0006 .004-.008 0.010
CRANKSHAFT BEARINGS
Connecting Rod Bearing To Crankshaft Main Bearing to Crankshaft
Clearance Selective Fit Clearance Selective Fit-
Thickness Thickness
Engine Desired Allowable Std. 8 Desired Allowable Std.-
5.0L (302 CID) MFI V-8 .0008-.0015 .0007-.0024 .0572-.0577 .0008-.0015b .0008-.0026c .0957-.0960d
5.8L (351 CID) MFI .0008-.0015 .0008-.0025 .0572-.0577 .0008-.0015b .0008-.0026 c
.0957-.0960d
W-V-8
5.8L (351 CID) MFI .0008-.0015 .0008-.0025 .0572-.0577 .0008-.0015b .0008-.0026c .0957-.0960d
Lightning W-V-8
b No.1 Bearing - .0001-.0015; all others - .0005-.0015.
c No.1 Bearing - .0001-.0020; all others - .0005-.0024.
d No.1 Upper only - .0961 - .0966; all others - .0957-.0962.
CONNECTING ROD, PISTON AND RINGS

Connecting Rod
Alignment Maximum
Total Difference
Rod to
Rod Length Crankshaft
Piston Pin Bore Rod Bearing Center to Assembled
Engine or Bushing 1.0. Bore 1.0'- Center Twlstb Bend c Side Clearanceb
5.0L (302 CID) MFI V-8 .9096-.9112 2.2390-2.2398 5.0885-5.0915 .015 .012 .010-.020
5.8L (351 CID) MFI .9097-.9112 2.4265-2.4273 5.9545-5.9575 .024 .012 .010-.020
W-V-8
5.8L (351 CID) MFI .9097-.9112 2.4265-2.4273 5.9545-5.9575 .024 .012 .010-.020
Lightning W-V-8
a Connecting rod bearing bore maximum out -of-round - .0004.
c Pin bushing and crankshaft bore must be parallel and in same vertical plane with specified total difference when measured at the ends
PISTON
Ring Groove Width
Dlameter8 Compression
Piston
to Bore
Clearance Piston Pin
Coded Coded .003 Oversize Selective Bore
Red Blue Coded Yellow Fit Diameter Top Bottom 011
5.0L (302 CID) 3.9989- 4.0001- 4.0013-4.0019 .0014- .9123- .060- .060- .1587-
MFIV-8 3.9995 4.0007 .0022 .9126 .061 .061 .1597
5.8L (351 CID) 3.9978- 3.9990- 4.0002-4.0008 .0015- .9123- .080- .080- .188-
MFIW-V-8 3.9984 3.9996 .0023 .9126 .081 .081 .189
5.8L (351 CID) 3.9984- 3.9996- 4.0008-4.0018 .0015- .9123- .080- .080- .188-
MFI Lightning 3.9990 4.0002 .0023 .9126 .081 .081 .189
W-V-8
a Measured at the piston pin bore centerline at 90° to the pin.

ALL RIGHTS RESERVED
03-018-66 Engines, 5.0l MFI V-8, 5.8l MFI v-a and 5.al MFI Lightning v-a 03-018-66
PISTON PIN
Diameter
To Piston Pin To Connecting
.001 .002 Bore Rod Bushing
Engine Length Standard Oversize Oversize Clearance- Clearance
5.0l (302 CID) MFI V-8 3.010-3.040 .9119- .9130- .9140- .0002- Interference Fit
.9124 .9133 .9143 .0004
5.8l (351 CID) MFI W-V-8 3.010-3.040 .9119- .9130- .9140- .0003- Interference Fit
.9124 .9133 .9143 .0005
5.8l (351 CID) MFI lightning 3.010-3.040 .9119- .9130- .9140- .0003- Interference Fit
W-V-8 .9124 .9133 .9143 .0005
a Selective fit.
PISTON RINGS
Ring Width Side Clearance- Ring Gap
Top Bottom Top Bottom Top Bottom
Com- Com- Com- Com- Com- Com-
Engine pression pression pression pression 011 pression pression Ollb
5.0l (302 CIC) MFI V-8 .0577- .0577- .0013- .0013- Snug .010-.020 .018-.028 .010-.040
.0587 .0587 .0033 .0033
5.8l (351 CID) MFI W-V-8 .0577- .0577- .0013- .0013- Snug .010-.020 .018-.028 .010-.040
.0587 .0587 .0033 .0033
b Steel rail.
OIL PUMP AND OIL CAPACITY

Engine 011 Capacity-
Relief
Valve
Spring
Pre88ure Rotor
Lb8.@ Drlve8haft to Relief Valve to Assembly Outer Race
Specified Hou81ng Housing End to Hou81ng U.S. Imperial
Engine Length Clearance Clearance Clearance Clearance Quarts Quarts Lltres
5.0l (302 CID) 10.6-12.2 .0015-.0030 .0015-.0030 .004 .001-.013 5 4.2 4.7
MFIV-8 @ 1.74 Maximum
5.8l (351 CID) 18.2..20.2 .0015-.0030 .0015-.0030 .004 .001-.003 5 4.2 4.7
MFIW-V-8 @2.49 Maximum
5.8l (351 CID) 18.2-20.2 .0015-.0030 .0015-.0030 .004 .001-.003 5 4.2 4.7
MFIW-V-8 @2.49 Maximum
a Add 1 U.S. quart (or equivalent in imperial quarts or liters) when replacing filter.
TORQUE LIMITS - 5.0L (302 CID) MFI V-8 W-V-8, 5.8L (351 CID) MFI LIGHTNING V-8
1/4-20 5/16-18 5/16-24 3/8-16 3/8-24 7 116-14 7/16-20 1/2-13 9/16-18
8-12 17-24 19-27 30-43 37-51 61-77 55-81 75-81 116-162
(6-9) (12-18) (14-20) (22-32) (27-38) (45-57) (40-60) (55-60) (85-120)
NOTE: All values in N·m (Ib-ft), unless otherwise noted. Oil threads with engine oil unless the threads require oil or
water-resistant sealer. The standard torque limits listed below are applicable for all functions not listed in the special
torque chart.
PIPE THREADS
1/8-27 114-18 3 I 8-18 1 12-14
7-11 (5-8) 17-24 (12-18) 30-44 (22-33) 34-47 (25-35)

ALL RIGHTS RESERVED
03-018-67 Engines, 5.0L MFI V-S, 5.SL MFI V-S and 5.SL MFI Lightning V-S- 03-018-67
TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS (Cont'd)

Description N·m Lb-Ft Lb-In Description H·m Lb-Ft Lb-In
Camshaft Sprocket - Gear to 54-61 40-45 - Air Conditioning Compressor 24-31 18-22 -
Camshaft to Bracket
Camshaft Thrust Plate to 13-16 9-12 - Power Steering Pump to 41-54 30-40 -
Cylinder Block Bracket
Connecting Rod Nut - 5.0L 26-33 19-24 - Thermactor Pump Holding Bolt 41-54 30-40 -
Connecting Rod Nut - 5.8L 54-61 40-45 - Alternator Attaching Bolt 41-54 30-40 -
Cylinder Front Cover 17-24 12-18 - Thermactor Pump and 41-54 30-40 -
Cylinder Head Bolts SEE NOTE Alternator Bracket to Cylinder
Head 3/8-16 Bolt
Damper to Crankshaft 95-122 70-90 -
Air Conditioning Compressor 54-71 40-50 -
EGR Valve to Carburetor 17-24 12-18 - and Power Steering Pump
Spacer or Intake Manifold Bracket to Head
Flywheel to Crankshaft 102-115 75-85 - Thermactor Pump Pivot Bolt 41-54 30-40 -
Main Bearing Cap Bolts - 82-95 60-70 - Thermactor Pump Pulley to 12-15 - 8.5-11
5.0L (302 CID) V-8 Pump Hub
Main Bearing Cap Bolts - 129-142 95-105 - Exhaust Pipe to Manifold 33-49 24-36 -
5.8L (351 CID) W-V-8
Manifold to Cylinder Head - 31-34 23-25 -
Heat Shield, Spark Plug 16-23 12-17 -
Intake Clutch-to-Fan Bolts 16-24 12-18 -
Upper to Lower Intake 17-24 12-18 - Fan and Clutch 16-24 12-18 -
Manifold Assembly-to-Pulley
Manifold to Cylinder Head - 24-32 18-24 - Dipstick Tube Bracket 16-24 12-18 -
Exhaust EGR Valve Studs 18-26 13-19 -
Intake Manifold Vacuum 8-13 6-10 - Exhaust Manifold Fitting Nut 61-75 45-55 -
Fittings - Aluminum
Upper Intake Manifold Support 16-24 12-18 -
Intake Manifold Pipe Fittings 17-24 12-18 - Bracket
-Aluminum
Oil Pump Screen Cover and 30-43 22-32 -
Secondary Air Injection 23-34 17-25 -
Manifold Tube - C6
Tube to Main Bearing Cap Transmission
Thermactor Pump Bracket to 44-67 30-45 - Vacuum Harness Bracket and 17-24 12-18 -
Cylinder Block Nut
Distributor Clamp Down 24-32 17-25 - EGR to Exhaust Manifold Tube
Oil Filter Insert to Cylinder 28-40 20-30 - Flange Nuts
Block / Adaptor Upper 41-54 30-40 -
Oil Filter to Adaptor or Cylinder 1/2 Turn After Gasket Lower 47-61 35-45 -
Block Contacts Sealing Surface - 5.0L Oil Level Indicator Tube to 16-23 12-17 -
Oiled Gasket Cylinder Block
Oil Inlet Tube Pump 14-20 10-15 - 5.8L Oil Level Indicator Tube to 16-24 12-18 -
Oil Pan Drain Plug 21-33 15-25 - Exhaust Manifold Stud
Oil Pan to Cylinder Block (18 9-14 - 84-120 NOTE: 5.0L MFI V-8 - Tighten in steps: first to 75-88
Places) N·m (55-65 Ib-ft) then to 88-97 N·m (65-72 Ib-ft).
Oil Pan to Cylinder Block (4 16-24 12-18 - 5.8L MFI W-V-8 - Tighten in steps: first to 115 N·m (85
Places) Ib-ft) then to 129 N·m (95Ib-ft), final to 143-151 N·m
(105-112 Ib-ft).
Oil Pump to Cylinder Block 30-43 22-32 -
Pulley to Damper Bolt 54-71 40-52 - GREASES, LUBRICANTS, SEALERS
Rocker Arm Stud / Bolt to 24-34 18-25 - AND ADHESIVES
Cylinder Head
Description Specification
Spark Plug to Cylinder Head 14-20 10-15 -
Multi-Purpose Grease DOAZ-19584-AA
Valve Cover 16-20 11-14 - (ESB-M 1C93-A)
Water Outlet Housing 13-16 9-12 - Lubricant SAE 50WT (ESE-M2C39-F)
Water Pump to Block / Front 20-28 15-21 - Silicon Rubber D6AZ-19562-BA
Cover (ESB-M4G92-A)
Thermactor Pump and 41-54 30-40 - Threadlock Sealer EOAZ-19554-AA
Alternator Bracket to Cylinder (ESE-M4G204-A5 (Type II»
Head - Bolt 3/8-16
(Continued)
(Continued)
ALL RIGHTS RESERVED
03-018-68 ~ Engines, 5.0L MFI V-8, 5.8L MFI V-8 and 5.8L MFI Lightning V-8 03-018-68
GREASES, LUBRICANTS, SEALERS

AND ADHESIVES (Cont'd)
De8crlptlon Specification
Perfect Seal Sealing B5A-19552-A (ESR-M 18P2-A)
Compound
Pipe Sealant with Teflon~ D8AZ-19554-A
WSK-M2G350-A2
Vehicle Emission Control Information (VECI) Decal
FORD MOTOR COMPANY VACUUM HOSE ROUTING
IMPORTANT VEHICLE INFORMATION

THIS VEHICLE IS EQUIPPED WITH EEC IV/EFt SYSTEMS. IDLE
SPEEDS AND IDLE MIXTURES ARE NOT ADJUSTABLE. SEE SHOP
MANUAL FOR ADDITIONAL INFORMATION.
ADJUST IGNITION TIMING WITH THE TRANSMISSION IN NEUTRAL.
PARKING BRAKE SET AND THE WHEELS BLOCKED. ENGINE MUST BE
AT NORMAL OPERATING TEMPERATURE.
IGNITION TIMING (I) TURN OFF ENGINE.
PROCEDURE (2) DISCONNECT THE IN-LINE SPOUT CONNECTOR ( -ocr OR -011 ).
3) RE-START PREVIOUSLY WARMED-UP ENGINE.
(5) TURN OFF ENGINE AND RESTORE ELECTRICAL CONNECTION.
FIRING ORDER - 1-5-4-2-6-3-1-8
ENGINE SPARK PLUG SPARK PLUG GAP ENGINE VACUUM HOSE

DISPLACEMENT TYPE SPECIFICATIONS ROUTING (TYPICAL) V7458·2B
SPECIAL SERVICE TOOLS REQUIRED SPECIAL SERVICE TOOLS REQUIRED (Cont'd)

"
Tool Number/ Tool Number/

De8crlptlon IIIu8tration De8crlptlon IIIu8tration
T59L-100-B T61P-6019·B-
Impact Slide Hammer Fron, .cover Aligner
~ TIK.·1GO-I
T58L-101-B
~
Puller T70P-6049-A
TSIL-101·8
T70P-6000
Engine Lifting Brackets
~~ T68P-6135-A
o
T70P-IOOO
T64L·6011-EA
OO~
•
Cylinder Ridge Reamer
.A1 ·A7 -1.2 .AJ -M -AI ·M
TIIP..131-A
TI4L~11-EA
(Continued)
(Continued)
ALL RIGHTS RESERVED

(Continued)
SPECIAL SERVICE TOOLS REQUIRED (Cont'd) SPECIAL SERVICE TOOLS REQUIRED (Cont'd)
Description illustration Description illustration
T65L-6250-A T71 P-6513-B
Camshaft Bearing Set Tappet Bleed Down Wrench
I EJ )
223~
~
c
• 0 T71P-I113-8
• •~ 000
TIIL~2IO-A T75L-6392-A
Clutch Housing Alignment Tool
T52L-6306-AEE
~
Crankshaft Damper & Sprocket
Replacer
TI2L-63OI-AEE T75L-I3I2-A
T58P-6316-D T82L-6701-A
~
Seal Replacer
® b~
TI2L-I701·A
TIIP-e311-D
SPECIAL SERVICE TOOLS
~~~
T79T-6316-A
Damper Remover / Replacer Tool Number Description
Tool
D80L-522-A Damper Remover
081 L-6002-C Piston Ring Compressor
D79L-6731-A Oil Filter Wrench
T71T-I31I-A
D79L-6731-B 011 Filter Wrench
T74P-6666-A D87L-9280-A Spring Lock Coupling Disconnect Tool
~
Spark Plug Wire Remover (3/8 Inch)
D87L-9280-B Spring Lock Coupling Disconnect Tool
(1/2Inch)
T74P.....A TOOL-4201-C Dial Indicator with Bracketry
T70P-6B070-B TOOL-6331-E Main Bearing Insert Tool
U
TOOL-6500-E Hydraulic Tappet Leakdown Tester
ROTUNDA EQUIPMENT
T70NBCJ7G.8
Model Description
T88T-6701-A
066-00017 Transmission Jack
~
Crankshaft Seal
Replacer / Cover Aligner
T88T-8701-A
T84L-19623-B
A / C Spring Lock Coupling
Disconnect Tool Set ~~
~~
T84L-11123-B
(Continued)
ALL RIGHTS RESERVED
03-01C-1 Engine, 7.5L MFI v-a 03-01C-1
SECTION 03-01C Engine, 7.5L MFI v-a

VEHICLE APPLiCATION •••••••••••••••••.•.•••••••••••••••..••••••03-01C-1 IN·VEHICLE SERVICE (Cont'd.)
DESCRIPTION AND OPERATION 011 Bypass Filter ••••••••••••••••••••••••••••••••••••••••••••••••03.o1C·42
Camshaft ••••••••••••••••••••••••••••••••••....••••••••••••••..•.••••03-01 C-3 011 Level Indicator Tube •••••••••••••••••••••••••••••••••••••03.o1C-45
Crankshaft •••.•••••••••••••••••.••••••••••••••••••••••••••••••••••.•03-01 C-3 Oil Pan and/or 011 Pump Screen Cover and
Drive Belt System ••••••••••••••••••••••••••..••••••••••••••••••••03-0 1C-6 Tube •••••••..•••••••••••••••••••••••••••••••••••••••••••••••••••••03-01 C-35
Emission Calibration Label •••••••••••••••••••••••••••••••.••03-01C-2 011 Pump•..•••••••.••••••••..•••••••••••••••••••••••••••••••••••••••03-o1C-37
Engine ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••03-01C-1 Pistons and Connecting Rods ••••••••••••••••••••••••••••03-01C-38
Engine Cooling System ••••••••••••••••••••••••••••••.••••••••03-01C-4 Removal ..•••••••••••••••..•••••••••••••••••••••••••••••••••••••••••03-01 C-25
Engine Identification •••••••••••••••••••••••••••••••••••••••••••03-01C-2 Removal ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••03.0 1C-28
Engine Lubrication System •••••••••••••••••.••••••••••••••••03-01 C-3 Rocker Arm •••••••••••••••••••••••••••••••••••••••••••••••••••••••03-01C-12
Exhaust Emission Control System ...••••••••••••••••••••03-01C-3 Sensors ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••03-01 C-45
Induction System •••••••••••••••••••••••••••••••••••••••...••••••03-01C-3 Engine ••....•••••••••••••••••••••••••••••••••••••••••••••••••••••03-01C-46
Positive Crankcase Ventilation System ••••••••••••••••03-01 C-3 011 Pressure Sender (Switch) ••••••••••••••••••••••••••03-01C-45
Valve Train •••••••••••••••••••••••••••••••.••••••••••••••••••••.•••••03-01C-3 TIming Chain and Sprockets ••••••••••••••••••••••••••••••03.o1C-28
IN·VEHICLE SERVICE Upper••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••03.o1C-15
Camshaft ••••••••••••••••••••••••••••••••••••..••••••••••••••••••••03-01 C-31 Valve Cover and Gasket 03-01C-11
Camshaft Bearings ••••••••••••••••••••.••••••••••••••...••••••03-01 C-49 Valve Spring, Retainer and Valve Stem
Camshaft Rear Bearing Cover •••••••••.••••••••••••••••••03-o1C-42 Seal ••••••••••••••••••••••••••••••••••••••••.••••••••••••••••••••••03-01 C-13
Connecting Rod Bearings ••••••••••••••••••••••••••••••.•••03-01 C-40 Valve Tappet, Hydraulic •••••••••••••••••••••••••••••••••••••03-01C-14
Crankshaft •••.••••••••••••••••••••••••••••••••••••••••••••••••••••03-01 C-51 Water Pump ••••••.••••••.....•••••••••••••••••••••••••••••••••••••03.o1C-24
Crankshaft Main Bearlngs••••••••••••••••••••••••••••••••••03-01C-37 DISASSEMBLY AND ASSEMBLY
Crankshaft Pulley and/or Damper and/or Engine ••••••.••••••••••••••••••••••••••••.•••••••••••••••••.••••••••03-Q1C-54
Crankshaft Front Seal ••••••••••••••••••••••.•••••••.•••••03-01C-23 Subassemblies ••••••••••••••••••••••••••••••••••••••••••••••••••03-0 1C-54
Crankshaft Rear 011 Seal •••••••••••••••••.••••••••.•••••••••03-o 1C-41 Cylinder Head •••••..••••••••••••••••••.••••••••••••••••••••••03.o1C·54
Cylinder Heads ••••••••••••••••••••••••••••••••••••••••••••....••03-01 C-19 Pistons, Piston Pins and Rlngs ••••••••••••••.•••••••••03-Q1C-55
Engine Components •••••..•••••••••••••••••••••••••••••••••••••03-01 C-6 Valve Tappet, Hydraulic ••••••• ~ •••••••••••••••••••••••••••••03-o1C-56
Engine Front Cover •••••••••••••••••••••••••••••••••••••••••••03-01C-25 Cylinder Block Assembly••••••••.•••••••••••••••..••••••03-o1C-57
Engine 011 Cooler •••••••••...••••••••••••••••••••••••••••••••••03-o1C-43 Cylinder Block, Bare .•••••••••••••••••••••••••••••••••••••03-Q1C-57
Exhaust Manifolds •••••••••••••••••••••••••••••••.•••••••••••.•03.0 1C.33 ADJUSTMENTS
Flywheel •••••••••••••••••••••••••••••••••••••••••••••••••••..••••••03-01C-40 Valve Clearance •.••••••••••••••••••••••••••••••••••••••••••••••03-Q1C·57
Intake Manifold •••••••••••••••••••••••••••..•••••••••••••••...••03-01C-15 SPECiFiCATIONS•••••••.••••••••••.••••••.•.••••••••••••••••••••••03-Q1C-58
Lower•••••••••••••••••••••••••••.••••••••••••••••••••••••••••.•••••••03-01C-17 SPECIAL SERVICE TOOLS/EQUIPMENT ••••••••••••••••03-01C-63
Malnshaft Bearing Roller••••••••••••••••••••••••••••••••••••03-01 C-41
VEHICLE APPLICATION
F-250, F-350, F-Super Duty Chassis Cab and
Motorhome Stripped Chassis
Engine The 7.5L (460 CID) MFI engine is optional for F-250,
F-350 and F-Super Duty.
The 7.5L (460 CID) MFI v-a
engine has a cast iron
cylinder block. The crankshaft is precision-cast,
nodular iron alloy and has five main bearings. The
pistons are hyper-eutectic cast aluminum alloy, tin
plated. Rocker arms are pedestal-mounted and the
valve tappets are hydraulic. Large intake valves and
exhaust valves with wear-resistant hard
chrome-plated stems provide optimum breathing. A
low-restriction air cleaner is utilized for maximum clean
air intake. Refer to the chart under Specifications for
complete specifications.
ALL RIGHTS RESERVED
03-01C-2 Engine, 7.5L MFI v-a 03-01C-2
For quick engine identification, refer to the Vehicle
Emission Control Information (VECI) Decal mounted
under the hood. This decal lists engine information
required for proper servicing of the engine. Refer to
Section 00-03 for further information. An engine
identification label is also attached to the engine. The
symbol code on the identification tag identifies each
engine for determining parts usage, for instance,
engine displacement and model year. The vehicle
identification number (VIN) also gives engine
information. The tenth digit identifies the engine. Refer
to Section 00-03 for further information.
Typical VECI Decal
I Ford Motor Company

H.1PORTA[·H ElJGItJE IUFORMATIO[J
This vehicle is equipped with electronic engine' oontrol systems. Engine Idle
speed. idle mixture. and ignition timing are not adjustabl~. See Powertrain
Cantrall Emissions Diagnosis Manual for additlonar information.
To check engine timing set parking brake and block wheels. Engine must be
at normal operating temperature. transmission in neutral. and accessories off.
~
(1) Turn off engine.
(2) Disconnect the in-line Spout Connector (=Od ).
(3) Re-start previously warmed-up engine. '--I ;-_.
~~
(4) Verify that the ignition timing is 100 BTOC. If not see shop manual.
(5) Turn engine off and restore electrical connection.
Use SAE10W-30 AMERICAN PETRCX.EUM INSTITUTE CERTIAED OILS foe GASOLINE ENGINES.
This engine conforms to U.S. EPA regulations 8POIJcabie to 1995 model year
new heavy-duty engines. This engine is certlfled for use In all heavy:ciuty
vehicles.
FSA.E.9C485- SplIt P\Jg: AM • 42C GIp: .042 ..046
lAC Catalyst 7.51· SFM1090AYCOA

SFM7.5D8GACA.m:OOXJAIRlH02S1EGRlSFI
A24036-A
Engine Code Information Emission Calibration Label

An engine code information label located on the valve The emission calibration number label is located on the
cover contains an engine build date, an engine plant left side door or left door post pillar. It identifies the
code and an engine code. engine calibration number, the engine code number
and revision level.
TYPICAL ENGINE CODE LABEL These numbers are used to determine if parts are
ENGINE CODe NOTE: It is critical that the engine codes and the
calibration number be used when ordering parts or
'"
NT;~~~~~~ III~III :
making inquiries about the engine.
CALIBRATION
ENGINE PLANT CODE

L-UMA
B-BRAZIL
~ ENGINE BUILD DATE
ErALONNAGE
CALIBRACION
~
CH-CHIHUAHUA A8312-e 2-54E-ROO E8AE-6E061-ABY

A10893-B
ALL RIGHTS RESERVED
03-01C-3 Engine, 7.5L MFI v-a 03-01C-3
Exhaust Emission Control System Valve Train

Operation, removal, installation and required A hydraulic valve tappet, providing automatic lash
maintenance of the exhaust emission control devices adjustment, rides on a camshaft lobe and transfers its
used on the 7.5L (460 CID) MFI engine are covered in up-and-down motion to the rocker arm through a push
the Powertrain Control/Emissions Diagnosis Manual. 1 rod. The rocker arms are pedestal-mounted and pivot
on rocker arm seats bolted to the cylinder head. The
intake valves and exhaust valves are arranged
alternately on the cylinder block.
Induction System
The fuel/air mixture needed for burning in the cylinders
is provided by Multiport Fuel Injection (MFI).
Positive Crankcase Ventilation System
Fuel is metered into each intake port in a sequential
firing order. Fuel injector nozzle tips pulse to follow The 7.5L (460 CID) MFI v-a
engine is equipped with a
engine firing order in accordance with engine demand positive closed-type crankcase ventilation system to
through fuel injector nozzle tips mounted on a tuned purge the crankcase vapors. The PCV valve is
intake manifold. threaded into the right-hand valve cover and is sealed
by a compression gasket.
The fuel delivery subsystem consists of a
high-pressure in-tank mounted fuel pump, and a fuel
filter / reservoir delivering fuel from the fuel tank
through a chassis-mounted 20 micron fuel filter
bracket to a fuel injection supply manifold.
Engine Lubrication System
Pressurized oil from the oil pump is directed through a
The fuel injection supply manifold incorporates .
drilled oil passage to the full-flow oil filter and from the
electrically actuated fuel injector nozzle tips directly
oil filter to main oil galleries intersecting the valve
above each of the engine's eight intake ports. The fuel
tappet guide bores. A drilled gallery (crossover) at the
injector nozzle tips, when energized, spray a metered
rear of the tappet chamber routes oil to the left bank.
quantity of fuel into the intake air stream.
The crankshaft main bearings, connecting rod
A constant fuel pressure drop is maintained across the bearings, and camshaft bearings are supplied with oil
injector nozzles by a fuel pressure regulator. The fuel from the right oil gallery.
pressure regulator is connected in series with the fuel
Oil flow to the camshaft sprocket and timing
injector nozzle tips and is positioned downstream from
chain / belt is through an annulus and drilled passage at
them. Excess fuel supplied by the fuel pump, but not
the front of the No. 1 camshaft bearing. Oil flow to the
required by the engine, passes through the regulator
rocker arms is through the valve tappets and up the
and returns to the fuel tank through a fuel return line.
push rods to the arms.
All 7.5L engines are equipped with an engine oil cooler.
The.engine oil cooler is block-mounted. The compact
Crankshaft oil-to-water heat exchanger mounts directly to the left
side of the engine, at the oil filter mounting pad.
The crankshaft is supported by five crankshaft
bearings and bearing caps. The crankshaft thrust main Oil Pump
bearing (No. 3 bearing insert) limits crankshaft end The heart of the lubrication system is a full-pressure
play and absorbs axial thrust loads applied to the cast-iron pump. The high capacity --G-rotor" pump is
crankshaft ends. The camshaft sprocket, crankshaft bolted to the bottom of the cylinder block and is driven
sprocket and timing chain / belt connect the crankshaft by a hex shaft from the distributor. The pressure is
with the camshaft and provide a 2: 1 drive ratio. relief-valve controlled. The oil pump draws oil from the
oil pan through an attached oil pump screen cover and
tube to provide the necessary volume of oil for engine
lubrication.
Camshaft
The camshaft is installed in the cylinder block and is
supported by five camshaft bearings is pressed into
the journal openings in the cylinder block. Thrust loads
and end play are limited by a camshaft thrust plate
installed at the front of the camshaft.

ALL RIGHTS RESERVED
03-01C-4 Engine, 7.5L MFI v-a 03-01C-4
Oil Pan
Part
The oil pan is a stamped steel part that bolts to the Item Description
Number
bottom of the cylinder block. The oil pan is a reservoir
for engine oil used by the oil pump to lubricate internal 3 - From Oil Cooler Back to
engine components. Engine
4 - From Oil Cooler
5 - To Oil Bypass Filter
Engine Cooling System

The cooling system is a series-parallel flow design.
Coolant flow is from the water pump through passages
in the engine front cover (both sides) to the cylinder
block. Flow continues through the cylinder block
toward the rear of the engine and into the cylinder
head at various transfer passages along the length of
the cylinder block deck. It then travels from the
cylinder heads to the water crossover at the front of
the intake manifold, through the water outlet
connection and to the top of the radiator.
SHOWING OIL PUMP

PRESSURE RELIEF AND
RECIRCULATION OF OIL
VIEW A
VIEW SHOWING ENGINE OIL

COOLER BY-PASS FEATURE
A18726-C
Part
1 9278 Oil Pressure Sensor
2 - From Engine to Oil Bypass
Filter to Oil Cooler
(Continued)

ALL RIGHTS RESERVED
03-01C-5 Engine, 7.5L MFI v-a 03-01C-5
7.5L Cooling System
Part Part
1 6049 Cylinder Head (RH) 11 6B856 Engine Oil Cooler
2 18476 Heater Core 12 6019 Engine Front Cover
3 18476 Heater Core 13 6B856 Engine Oil Cooler
4 6010 Cylinder Block (RH Bank) 14 8005 Radiator
5 8501 Water Pump 15 8501 Water Pump
6 6010 Cylinder Block (LH Bank) 16 18476 Heater Core
7 6051 Head Gasket 17 6007 Engine
8 6049 Cylinder Head (LH) 18 8575 Water Thermostat
9 8592 Water Hose Connection 19 8592 Water Hose Connection
10 8A080 Radiator Coolant Recovery
Reservoir
(Continued)

ALL RIGHTS RESERVED
03-01C-6 Engine, 7.5L MFI v-a 03-01C-6
Drive Belt System When installing nuts or bolts (refer to Torque

Accessories mounted on the front of the engine are Specifications listed at the end of this section), oil the
belt-driven by the crankshaft using two 6K Poly-Vee threads with lightweight engine oil. Do not oil threads
drive belts. One drive belt is routed over the air pump requiring oil-resistant or water-resistant sealer.
pulley, generator pulley, water pump pulley and the
crankshaft pulley. The other drive belt is routed over
the water pump pulley, automatic tensioner pulley, air
conditioning compressor pulley or idler pulley (if Engine Components
equipped), power steering pump pulley and the The following exploded views of the 7.5L MFI engine
crankshaft pulley. (6007) are typical and are references for procedures
outlined. The parts descriptions and basic numbers in
the illustration keys correspond with the Ford Master
IN-VEHICLE SERVICE Parts Catalog.
The following procedures can be performed with the

engine (6007) in the vehicle.

ALL RIGHTS RESERVED
03-01C-7 Engine, 7.5L MFI V-8 03-01C-7
7.5L MFI (460 CID) V-8 Engine, External Exploded View
A23475·A
ALL RIGHTS RESERVED
03-01C-8 Engine, 7.5L MFI v-a 03-01C·8
Part Part
1 9E527 Fuel Injector Nozzle Tip 43 6A008 Cylinder Head to Block
Bolt (4) Dowel (4)
2 N802626
9F792 Fuel Injection Supply 44 7007 Engine Rear Plate
3
Manifold 45 57658 Bolt
4 6C324 Crankcase Vent Connector 46 6375 Flywheel
and Hose 47 390639 Bolt
5 390768 Bolt (8) 48 6584 Valve Cover Gasket (2)
6 6A532 Washer (8) 49 6582 Valve Cover (LH)
7 6582 Valve Cover (RH) 50 6766 Oil Filler Cap
8 W623842 Washer (8) 51 56559 Bolt
9 6K780 Positive Crankcase 52 42997 Bolt
Ventilation Valve Gasket 53 17A084 Engine Lifting Eye (LH Rear)
10 6A666 Positive Crankcase 54 90477 EGR Valve to Exhaust
Ventilation Valve Manifold Tube
11 9F715 Idle Air Control Valve 55 N801906 Elbow
12 N605893 Bolt (2) 56 33771 Nut (4)
13 390774 Bolt (4) 51 12A406 Spark Plug Heat Shield (LH)
14 9E926 Throttle Body 58 6065 Bolt (10)
15 9E936 Throttle Body Gasket 59 371485-S Insert (6)
16 9424 Intake Manifold. Upper 60 6065 Bolt (10)
17 386153 Nipple 61 6051 Head Gasket
18 389642 Nipple 62 6049 Cylinder Head (2)
19 90476 EGR Valve Gasket 63 9431 Exhaust Manifold (LH)
20 9F483 EGR External Pressure Valve 64 6750 Oil Level Dipstick
21 390715 Stud (2) 65 6754 Oil Level Indicator Tube
22 390712 Bolt (4) 66 N808064-S 100 Clip
23 9H486 Intake Manifold Upper 67 391496·S2 Bolt (23)
Gasket
24 12A697 Intake Air Temperature
69 6734 Washer
Sensor
70 6675 Oil Pan
Outlet Fitting and Cap 71 6710 Oil Pan Gasket
26 12648 Sensor 72 6894 Bolt
27 10884 Water Temperature Indicator 73 6B856 Engine Oil Cooler
Sender Unit 74 6890 Oil Filter Mounting Insert
28 358720 Bolt (2) 75 391001 Clamp
29 8592 Water Hose Connection 76 6714 Oil Bypass Filter
30 8255 Water Outlet Connection 77 8507 Water Pump Housing Gasket
Gasket 78 8508 Water Pump Cover
31 38768 Fitting 79 8513 Water Pump Cover Gasket
32 8575 Water Thermostat 80 8501 Water Pump
33 9A474 Intake Manifold Vacuum 81 6020 Engine Front Cover Gasket
Outlet Fitting and Cap 82 6700 Crankshaft Front Seal
34 9424 Intake Manifold. Lower 83 389772 Clamp (2)
35 - Intake Manifold Gasket 84 8548 Water Bypass Tube Or Hose
(Part of 9433)
85 18599 Hot Water Heater Elbow
36 9430 Exhaust Manifold (RH) Connection
37 - Seal. Intake 86 6023 Timing Pointer
Manifold-to-Cylinder Block
(Part of 9433) 87 6019 Engine Front Cover
38 - Seal. Intake 88 56559 Bolt
Manifold-to-Cylinder Block 89 42997 Bolt
(Part of 9433) 90 17A084 Engine Lifting Eye (RH Front)
39 6500 Valve Tappet (16) 91 12127 Distributor
40 6266 Camshaft Rear Bearing 92 12270 Hold-Down Clamp
Cover 93 12390 Gear
41 6397 Flywheel Housing to Block 94 12127 Distributor
Dowel (2)
95 42955 Bolt
(Continued)
(Continued)
1995 F·150. F-250, F-350, Bronco, F"Super Duty Powertrain, Drivetrain July 1994
ALL RIGHTS RESERVED
03-01C-9 Engine, 7.5L MFI V-8 03-01C-9
Part Part
96 12A217 Distributor Base Adapter 98 12286 Distributor to Spark Plug
97 12106 Distributor Cap Wire
(Continued)
99 12297 Ignition Wire Separator
ALL RIGHTS RESERVED
03-01C-10 Engine, 7.5L MFI V-8 03-01C-10
7.5L MFI (460 CID) V-8 Engine, Internal Exploded View
A10742-c

ALL RIGHTS RESERVED
03-01C-11 Engine, 7.5L MFI v-a 03-01C-11
Part Part
1 6565 Push Rod (16) 36 57647-S Bolt (2)
2 6564 Rocker Arm (16) 37 376706-S Bolt
3 6A528 Rocker Arm Seat (16) 38 6378 Washer
4 385658-S2 Bolt (16) 39 6316 Crankshaft Vibration
5 6518 Valve Spring Retainer Key Damper
(32) 40 74151-5 Key
6 6514 Valve Spring Retainer (16) 41 6359 Crankshaft Damper Spacer
7 6513 Valve Spring (16) 42 6306 Crankshaft Sprocket
8 6571 Valve Stem Seal (8) 43 6268 Timing Chain
9 6065 Bolt (10) 44 6212 Nut (16)
10 6065 Bolt (10) 45 6211 Connecting Rod Bearing (8)
11 6571 Valve Stem Seal (8) 46 6200 Connecting Rod (8)
12 371485-S Insert (6) 47 6214 Bolt (16)
13 12405 Spark Plug (8) 48 6135 Piston Pin (8)
14 6507 Intake Valve (8) 49 6102 Piston, Pin and Ring (8)
15 6505 Exhaust Valve (8) 50 6148 Partial Piston 'Ring Set (8)
16 6049 Cylinder Head 51 6337 Crankshaft Thrust Main
17 43001-S2 Bolt Bearing
18 6278 Washer 52 6333 Crankshaft Main Bearing
(4 Places)
19 73328 Dowel
53 6303 Crankshaft
21 42910-S Bolt (2)
55 6397 Flywheel Housing to Block
22 6269 Camshaft Thrust Plate Dowel (2)
23 6250 Camshaft 56 7007 Engine Rear Plate
24 6261 Camshaft Bearing (5) 57 57658-S2 Bolt
25 6010 Cylinder Block 58 6375 Flywheel
26 87837-S Plug 59 390639-5 Bolt
27 6500 Valve Tappet (16)
60 - Crankshaft Main Bearing
Cap (Part of 6010)
Cover 61 386574-S Bolt (9)
29 6A008 Cylinder Head to Block 62 388488-S Stud
Dowel (4)
30 6600 Oil Pump
Cap (Part of 6010)
31 6A618 Oil Pump Intermediate Shaft
32 358761-S Bolt (2)
Cap (Part of 6010)
33 382802-S2 Nut 65 - Crankshaft Main Bearing
34 6622 Oil Pump Screen Cover and Cap (Part of 6010)
Tube 66 - Crankshaft Main Bearing
35 6626 Oil Pump Inlet Tube Gasket Cap (Part of 6010)
(Continued)
Valve Cover and Gasket 3. Disconnect distributor to spark plug wires

(12286) from spark plugs (12405) using Spark
SPECIAL SERVICE TOOL(S) REQUIRED Plug Wire Remover 174P-6666-A and position
distributor to spark plug wires out of the way.
4. Remove positive crankcase ventilation valve
Spark Plug Wire Remover T74P-6666-A (PCV valve)(6A666) from the valve cover (6582)
(for right valve cover).
Removal
5. Position wiring and vacuum harnesses to gain
1. Disconnect battery ground cable (14301). access in order to remove right valve cover.
2. On the right side of the engine (6007), disconnect 6. Remove attaching bolts and remove the valve
the secondary air injection system, including covers.
brackets, and position out of the way. On the left
side of the engine, remove the ignition coil 7. Remove the valve cover gasket (6584) from the
mounting strap (12043) and position out of the valve covers(s).
way.

ALL RIGHTS RESERVED
03-01C-12 Engine, 7.5L MFI V-8 03-01C-12
Installation 2. NOTE: Make sure rocker arm seat is oriented in

1. Clean valve cover and cylinder head sealing the rocker arm as originally removed.
surface. Position valve cover gasket in valve Position the No. 1 piston (6108) at TOC at the
cover seal groove, making sure that the valve end of the compression stroke (Position No.1).
cover gasket tang is aligned with notch in the Install the rocker arm, rocker arm seat, and
valve cover. rocket arm seat bolt on the following intake
2. Position valve covers(s) on the cylinder head valves (6507) and exhaust valves (6505):
(6049). Starting with rearmost bolt and working No. 1 intake valve No. 1 exhaust valve
forward. tighten the four valve cover bolt and No.3 intake valve No.8 exhaust valve
washer assemblies to 12-15 N·m (9-11 Ib-ft).
No.7 intake valve No.5 exhaust valve
3. Install positive crankcase ventilation valve with
gasket into right valve cover. No.8 intake valve No.4 exhaust valve
4. Reconnect distributor to spark plug wires at Make sure the rocker arm seat base is inserted into its
spark plugs. Install ignition coil mounting strap. slot on the cylinder head (6049) before tightening the
rocker arm seat bolts. Tighten the rocker arm seat
5. Connect secondary air injection bypass valve and bolts to 25-34 N·m (18-25Ib-ft).
bracket assembly.
3. Position the crankshaft (6303) in Position No. 1
6. Install secondary air injection air supply tube and and install the rocker arm. rocker arm seat, and a
hose at secondary air injection bypass valve. rocker arm seat bolt on the following intake
7. NOTE: When the battery has been disconnected valves and exhaust valves:
and reconnected. some abnormal drive No.2 intake valve No.2 exhaust valve
symptoms may occur while the powertrain
control module (PCM)( 12A650) relearns its No.4 intake valve No.3 exhaust valve
adaptive strategy. The vehicle may need to be No.5 intake valve No.6 exhaust valve
driven 10 miles or more to relearn the strategy.
No.6 intake valve No. 7 exhaust valve
Connect battery ground cable.
TIMING
POINTER
Rocker Arm 6023
Removal
1. Remove the valve cover (6582). Refer to Valve
Cover and Gasket in this section.
2. Remove rocker arm seat bolt, rocker arm seat
(6A528) and rocker arm (6564).
ROCKER A R M - - t POSITION 1 - NO.1 AT TOC AT END OF COMPRESSION STROKE.

SEAT BOLT
385858-S2 POSITION 2 - ROTATE THE CRANKSHAFT 360 DEGREES
(ONE REVOLUTION) CLOCKWISE FROM POSITION 1.
A7908-B
ROCKER
11-....- ARM SEAT
6A528 Make sure the rocker arm seat base is inserted into its
slot on the cylinder head before tightening the rocker
arm seat bolts. Tighten the rocker arm seat bolts to
25-34 N·m (18-25Ib-ft). Adjust the valve clearance.
ROCKER
ARM Refer to Adjustments in this section.
8584
4. Install valve cover and gasket. Refer to Valve
Cover and Gasket in this section.
A3238-E
Installation
1. Apply Ford Multi-Purpose Grease
DOAZ-19584-AA or equivalent meeting Ford .
specification ESR-M 1C 159-A to the top of the .
intake and exhaust valve stems, the rocker arms
and rocker arm seats.

ALL RIGHTS RESERVED
03-01C-13 Engine, 7.5L MFI v-a 03-01C-13
Valve Spring, Retainer and Valve Stem Seal 4. If air pressure has forced the piston (6108) to the
If the intake valve (6507) or exhaust valve (6505) has bottom of the cylinder, any removal of air
not been damaged, the valve spring (6513), valve pressure will allow the intake valve or exhaust
stem seals (6571), valve spring retainer key (6518) valve to fall into the cylinder. A rubber band, tape
and valve spring retainer (6514) may be replaced by or string wrapped around the end of adjacent
holding the affected intake valve or exhaust valve valve stems will prevent this condition and will still
against its seat using compressed air. Use an allow enough travel to check the intake valve or
appropriate air line tool installed in the spark plug hole. exhaust valve for binds.
A minimum of 965 kPa (140 psi) line pressure is 5. Inspect the valve stem for damage. Rotate the
required. intake valve or exhaust valve and check the stem
NOTE: If air pressure does not hold the intake valve or tip for eccentric movement. Move the intake valve
exhaust valve shut, the intake valve or exhaust valve or exhaust valve up and down through normal
is damaged and the cylinder head (6049) must be travel in the valve guide and check the stem for
removed and serviced. Refer to Section 03-00. binds. If the intake valve or exhaust valve has
been damaged, it will be necessary to remove the
cylinder head and service. Refer to Section 03-00
for cylinder head repair procedures.
Installation
Valve Spring Compressor T71 P-6565-A
1. NOTE: Unique exhaust and intake guide-mounted
Valve Seal Replacer T73P-6571-A
valve stem seals are required and care should be
used to install the correct valve stem seal in the
Removal appropriate location. The valve stem seals are
1. Remove the valve cover (6582). Refer to Valve identified on one end with IN for intake and EX for
Cover and Gasket in this section. exhaust.
2. Removetherockerarm(6564)androckerarm Install new valve stem seals as follows:
seat (6A528). Refer to Rocker Arm in this a. With intake valves and exhaust valves in
section. cylinder head, place plastic installation cap
3. Using Valve Spring Compressor T71 P-6565-A over end of valve stem. Lubricate the surface
compress the valve spring and remove the valve of the plastic cap to aid seal installation.
spring retainer keys, valve spring retainer, and b. Slide valve stem seal carefully over cap and
valve spring. Remove and discard the valve stem push valve stem seal down until jacket
seal. touches top of valve guide.
c. Remove plastic installation cap. Using Valve
Seal Installer T73P-6571-A push the valve
stem seal down until it bottoms on the valve
guide.
2. Apply Ford Multi-Purpose Grease
specification ESB-M 1C93-A to all contact
surfaces of the rocker arm. Install push rod
(6565). Install rocker arm and rocker arm seat.
Refer to Rocker Arm as described in this section.
A10098·B

ALL RIGHTS RESERVED
03-01C-14 Engine, 7.5L MFI v-a 03-01C-14
3. Install the valve cover. Refer to Valve Cover and 3. Remove the push rods. Keep push rods in
Gasket in this section. sequence so they can be installed in their original
locations.
4. Remove the valve tappets with a magnet. Place
PLASTIC INSTALLATION CAP them in a rack in sequence. Rotate valve tappets
(OIL SURFACE OF CAP TO back and forth to loosen them from gum or
FACILITATE SEAL INSTALLATION) varnish deposits.
TOOL-T73P-6571-A Refer to Section 03-00 for cleaning, inspection and
SHOULD CONTACT testing procedures. If necessary to disassemble valve
SHOULDER tappet(s), refer to Valve Tappet Disassembly and
Assembly.
Installation
1. Clean the outside of valve tappets. Valve tappets
and bores are to be lubricated with recommended
engine oil before installation. Install the valve
tappets into their original bores. Check any new
valve tappet for free fit in bore to which it is to be
installed. Prior to installation of a new valve
tappet, make sure valve tappet is full of oil by
working the valve tappet plunger up and down
until the valve tappet fills with fluid and all traces
of air bubbles has disappeared.
STEP NO.1 STEP NO.2 STEP NO.3
A7071-D 2. Install push rods in original positions. Apply Ford
4. Install the spark plug (12405) and tighten to 7-14 equivalent meeting Ford specification
N·m (5-10 Ib-ft). ESB-M 1C93-A to valve stem tips and push rod
ends.
3. Position the rocker arms over the push rods.
Tighten the rocker arm seat bolts following the
Valve Tappet, Hydraulic procedure under Rocker Arm Installation.
The following procedure is applicable for removing one 4. Install valve covers. Refer to Valve Cover and
or all of the valve tappets (6500). Before replacing a Gasket in this section.
hydraulic valve tappet for noisy operation, make sure 5. Install upper intake manifold and throttle body.
the noise is not caused by improper valve clearance or Refer to Intake Manifold, Upper in this section.
by worn rocker arms (6564) and / or push rods (6565).
Removal
1. Remove upper intake manifold (9424) and
throttle body (9E926). Refer to Intake Manifold,
Upper in this section.
2. Remove the valve covers (6582). Refer to Valve
Cover and Gasket in this section. Loosen the
rocker arm seat bolts and turn rocker arms to one
side.

ALL RIGHTS RESERVED
03-01C-15 Engine, 7.5L MFI V-8 03-01C-15
Intake Manifold
Part
Throttle Body and Upper Intake Manifold Assembly Item Number Description
4 9F715 Idle Air Control Valve
5 9E936 Throttle Body Gasket
6 90476 EGR Valve Gasket
7 9F670 Idle Air Control Gasket
8 390774-S8 Bolt, 5/ 16 x 1.5 Hex-Head
UBS (6 Req'd)
9 N605893-S8 Bolt, M6 x 25mm Hex-Head
UBS (2 Req'd)
10 390715-S36 Stud, 5/16-18 x 18 x 2.605
Hex Shoulder Pilot Stud
11 389642-S8 Connector, 3/8 Hose x 3/8
External Pipe
12 386163-S101 Connector, 1/4 Hose x 3/8
External Pipe
Upper
Removal
1. Remove air cleaner outlet tube (98659).
3. Disconnect throttle linkage at throttle ball and
automatic transmission linkage, if equipped, from
throttle body (9E926). Remove two bolts
securing bracket to upper intake manifold (9424)
and position bracket with cables out of the way.
4. Disconnect electrical connectors at:
a. idle air control valve (lAC valve)(9F715)
b. throttle position sensor (TP sensor)(98989)
c. EGR valve sensor (9G428)
5. Disconnect upper intake manifold vacuum fitting
connections by disconnecting:
a. vacuum line to MAP sensor
VIEW A b. vacuum line to EGR external pressure valve
V5863-F (9F483)
6. Disconnect EGR and PCV systems by
Part disconnecting:
Item Number Description a. EGR valve flange nut
1 9424 Intake Manifold b. PCV hose at rear of upper intake manifold
(Continued)
ALL RIGHTS RESERVED
03-01C-16 Engine, 7.5L MFI v-a 03-01C-16
7. Disconnect idle air control valve clean air supply

hose, connected to idle air control valve port. Part
(10-19 Lb-Ft)
8. Remove four upper intake manifold retaining

bolts.
9. Remove upper intake manifold and throttle body
assembly.
GASKET
~---9H488
V5888-E
Installation
VIEW A
A23626-A and upper intake manifolds.
Part 2. Position new gasket on lower intake mounting
face. The use of alignment studs may be helpful.
3. Install upper intake manifold and throttle body to
lower intake manifold, making sure gasket
2 98989 Throttle Position Sensor remains in place (if alignment studs are not used).
3 9G428 EGR Valve Sensor
4 9F483 EGR External Pressure Valve 4. Install four upper intake manifold retaining bolts.
lighten to specification.
5 386153-S101 Nipple for EGR Vacuum
Supply Hose 5. Install EGR valve to exhaust manifold tube
6 90477 EGR Valve to Exhaust (90477).
Manifold Tube
6. Connect PCV hose to rear of upper intake
7 6A666 Positive Crankcase manifold.
Ventilation Valve
8 6K780 Positive Crankcase 7. Connect vacuum lines to MAP sensor and EGR
Ventilation Valve Gasket external pressure valve.
9 6582 Valve Cover 8. Position throttle linkage bracket with cables to
10 6C324 Crankcase Vent Connector upper intake manifold. Install two attaching bolts
and Hose and tighten to specification. Connect throttle
A - Tighten to 34-65 N·m cable and automatic transmission kickdown cable
(25-48 Lb-Ft) to throttle body.
(Continued)

ALL RIGHTS RESERVED
03-01C-17 Engine, 7.5L MFI v-a 03-01C-17
9. Connect electrical connectors at idle air control

valve, throttle position sensor, and EGR valve
sensor.
10. Connect idle air control valve clean air supply
hose.
11. NOTE: When the battery has been disconnected
and reconnected, some abnormal drive
control module (PCM)( 12A650) relearns its
adaptive strategy. The vehicle may need to be
((2--..-
Connect battery ground cable. TWIST AND PULL
12. Install air cleaner outlet tube. B3498-E
11. Remove distributor (12127). Refer to Section

03-07A.
Lower Disconnect accelerator linkage and transmission
kickdown linkage at the throttle body (9E926).
SPECIAL SERVICE TOOL(S) REQUIREb Remove speed control linkage bracket, if so
equipped, from the upper intake manifold and
Description Tool Number disconnect it from the throttle body. Remove
Spark Plug Wire Remover T74P-6666-A bolts holding accelerator linkage cable, and
position linkage out of way.
Removal 12. Perform all pre-service procedures. Refer to
1. NOTE: On F-250, F-350 vehicles, it is possible to Section 03-04C. Using Disconnect Tool
remove upper intake manifold (9424) and lower D87L-9280-A or -B or equivalent, disconnect fuel
intake manifold as an assembly. lines at fuel injection supply manifold (9F792).
Remove air cleaner outlet tube (9B659) and 13. Disconnect engine wiring harness from main
engine air cleaner (ACL)(9600). wiring harness engine. Engine wiring harness and
lower intake manifold to be removed as an
2. Disconnect battery ground cable (14301). assembly.
3. Position a drain pan and drain radiator (8005). 14. Disconnect engine vacuum harness from vacuum
4. Remove secondary air injection system from right reservoir at right-hand fender apron.
side of engine (6007). 15. Remove attaching bolts. Remove lower intake
5. Remove ignition coil mounting strap (12043) from manifold using engine lifting eyes (17A084). If
engine and remove high tension lead at the necessary to pry lower intake manifold away
ignition coil (12029). from the cylinder heads (6049), do not
6. Disconnect and remove EGR valve to exhaust damage the gasket sealing surfaces.
manifold tube (90477). 16. Remove and discard intake manifold gaskets and
7. Disconnect upper radiator hose (8260) at engine. front and rear intake manifold-to-cylinder block
seals.
8. Disconnect heater hoses at lower intake manifold
and water pump (8501). Loosen water bypass 17. Transfer components as required.
tube or hose (8548) at lower intake manifold. 18. Remove all gasket material from the machined
9. Disconnect positive crankcase ventilation valve surfaces of the lower intake manifold. Clean the
(PCV valve)(6A666). Disconnect all the vacuum lower intake manifold in a suitable solvent and dry
lines at rear of lower intake manifold and tag them it with compressed air.
for reference during installation. 19. Inspect the lower intake manifold for cracks,
10. Disconnect distributor to spark plug wires damaged gasket surfaces, or other wear or
(12286) at the spark plugs (12405) using Spark damage that would make it unfit for further
Plug Wire Remover T74P-6666-A and move out service. Replace all fasteners that are stripped or
of the way. Disconnect and remove the distributor otherwise damaged. Remove all filings and
cap (12106) and distributor to spark plug wires foreign matter that may have entered the lower
intake manifold as a result of repairs.
as an assembly.
Installation
1. Clean mating surfaces of lower intake manifold,
cylinder heads, and cylinder block (6010). Use a
solvent such as Extra Strength Spot and Stain
Remover B7A-19521-AA or equivalent meeting
Ford specification ESR-M5B 197-A.
1995 F-150, F-250" F-350, Bronco, F-Super Duty Powertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
03-01C-18 Engine, 7.5L MFI V-8 03-01C-18
2. Apply a 3.175mm (1 18-inch) diameter bead of 5. NOTE: When lower intake manifold is in place, run
Gasket Maker E2AZ-19562-B or equivalent finger around seal area to make sure front and
meeting Ford specification WSK-M2G348-A5 in rear intake manifold-to-cylinder block seals are in
and along the joint, the full width of the cylinder place. If front and rear intake manifold-to-cylinder
block seal mounting surface (four corners) as block seals have shifted, remove lower intake
shown in the following illustration. manifold and reposition front and rear intake
3. Install the front and rear intake manifold-to-cylinder block seals.
manifold-to-cylinder block seals. Press front and Carefully place lower intake manifold into
rear intake manifold-to-cylinder block seals firmly position over four studs in ends of cylinder heads.
into place, distributing sealer into junction of 6. Make sure intake manifold gaskets are properly
cylinder block and cylinder head as shown. aligned. Then, install attaching bolts and stud
bolts into holes 1 through 10.
NOTE: LOWER INTAKE MANIFOLD-

9J447 SHOWN SIMPUFIED TO
ClARIFY INSTALLAnoN A10888-D
APPUCATION OF SEALER SEAL INSTALLAnON,
TYPICAL (4) PLACES TYPICAL (4) PLACES 7. Install bolts into holes 11 and 12.
VIEW A VIEW A 8. The lower intake manifold fasteners are secured
A1 following a three-step rundown procedure.
8. Install nuts onto studs 13 through 16. Tighten
Part
bolts 1 through 12 in sequence to 11-16 N·m
Item Number Description (8-12 Ib-ft). Tighten nuts 13 through 16 in
1 - Seal, Intake sequence to 11-16 N·m (8-12Ib-ft).
Manifold-to-Cylinder Block
(Part of 9433) b. Tighten bolts and nuts 1 through 16 in
sequence to 16-30 N·m (12-22 Ib-ft).
2 - Intake Manifold Gasket
(Part of 9433) c. Tighten bolts and nuts 1 through 16 in
3 6049 Cylinder Head sequence to 30-47 N·m (22-35Ib-ft).
4 6010 Cylinder Block d. Repeat Step c to make sure intake manifold
5 E2AZ-19562-B Gasket Maker (4 Places) is now fully seated.
4. Install intake manifold gasket.

ALL RIGHTS RESERVED
03-01C-19 Engine, 7.5L MFI v-a 03-01C-19
9. Install EGR valve to exhaust manifold tube and 2. Remove upper intake manifold (9424) and lower
~ secondary air injection system. intake manifold as an assembly. Refer to Intake
10. Install water bypass tube or hose to lower intake Manifold, Lower in this section.
manifold. 3. Disconnect muffler inlet pipe at left exhaust
11. Connect upper radiator hose to engine. manifold (9431) and right exhaust manifold
(9430).
12. Rotate crankshaft vibration damper (6316) until
No. 1 piston is at TDC at end of compression 4. Remove drive belts (8620). Refer to Section
stroke. Install the distributor. Refer to Section 03-05.
03-07A. 5. Remove secondary air injection pump (AIR
13. Connect heater hoses at lower intake manifold pump)(9A486) and generator (GEN)(10300).
and water pump. 6. Remove the generator mounting bracket (10153)
14. Connect positive crankcase ventilation valve. from the right cylinder head (6049).
15. Connect fuel lines to fuel injection supply manifold. 7. If equipped, discharge the air conditioning system
into an approved refrigerant recovery system.
16. Install ignition coil mounting straps. Refer to Section 12-00 in the Body, Chassis
17. Complete all electrical connections. Manual. Follow all safety precautions. Remove
hose assembly from rear of A I C compressor
18. Position accelerator linkage on upper intake (19703). Remove bolts attaching A/C
manifold. Attach accelerator linkage cable. compressor to A I C compressor mounting
Attach speed control linkage bracket to upper bracket (2882).
intake manifold, if so equipped. Install accelerator
and kickdown linkage to throttle body. 8. Remove nut attaching A I C compressor mounting
bracket to water pump (8501). Remove bolts
19. Connect the vacuum lines to their respective attaching A I C compressor mounting bracket to
ports at rear of lower intake manifold. front of cylinder head. Swing A/C compressor
20. Secure distributor cap to distributor. Connect mounting bracket out of the way with power
distributor to spark plug wires to spark plugs. steering pump (3A674) still attached.
Connect high tension lead to ignition coil. 9. Remove valve cover (6582). Remove rocker arm
21. Fill and bleed the cooling system. Refer to seat bolts, rocker arms (6564), rocker arm seats
Section 03-03. (6A528) and push rods (6565) in sequence so
22. NOTE: When the battery has been disconnected they can be installed in their original positions.
and reconnected, some abnormal drive 10. Remove cylinder head attaching bolts. Lift
symptoms may occur while the powertrain cylinder heads and left exhaust manifold or right
control module (PCM)( 12A650) relearns its exhaust manifold as assemblies from cylinder
adaptive strategy. The vehicle may need to be block (6010) with a hoist or other suitable lifting
driven 10 miles or more to relearn the strategy. device. If necessary to loosen head gasket
Connect the battery ground cable. seal, pry at forward corners of cylinder
heads against casting bosses provided on
23. Perform all post-service procedures. Refer to cylinder block. Do not damage machined
Section 03-04C. surfaces of cylinder head or cylinder block.
24. Start engine. Check and adjust ignition timing, if Discard head gasket (6051).
necessary. 11. If disassembly or machining of cylinder head is
25. Operate engine at fast idle and check for coolant .required, remove left exhaust manifold or right
leaks. Check coolant level and refill as exhaust manifold.
necessary. Installation
26. Start the engine and allow it to reach normal 1. Clean cylinder head, intake manifold, valve cover,
operating temperature. Then, while hot, tighten and cylinder block sealing surfaces. If cylinder
the lower intake manifold attaching nuts and bolts head was removed for head gasket replacement,
to 30-47 N·m (22-35Ib-ft). check flatness of cylinder head and cylinder
27. Install engine air cleaner and air cleaner outlet block gasket surfaces for flatness. Refer to
tube assembly. Section 03-00. If left exhaust manifold or right
exhaust manifold was removed, coat cylinder
head and exhaust manifold port areas with film of
Premium Long-Life Grease XG-1-C or -K or
Cylinder Heads equivalent meeting Ford specification
ESA-M 1C75-B and install left exhaust manifold or
Removal right exhaust manifold to cylinder head.
1. Disconnect battery ground cable (14301). Drain
cooling system.

ALL RIGHTS RESERVED
03-01C-20 Engine, 7.5L MFI v-a 03-01C-20
2. Place two long cylinder head attaching bolts in 7. lighten muffler inlet pipe stud nuts to 34-49 N·m
two rear lower bolt holes of left cylinder head. (25-36 Ib-ft).
Place a long cylinder head attaching bolt in rear 8. Install upper and lower intake manifold assembly.
lower bolt hole of right cylinder head. Use rubber Refer to Intake Manifold, Upper in this section.
bands to retain bolts in position, above
head-to-block mating surface, until cylinder heads 9. Check valve clearance. Refer to Adjustments in
are installed. this section.
3. Position new head gaskets on cylinder block over 10. Install valve covers and retaining bolts. lighten
cylinder head to block dowels (6A008). Do not bolts to 12-15 N·m (9-11 Ib-ft).
apply sealer to head gasket surfaces. Place 11. Install A I C compressor mounting bracket, with
cylinder heads on cylinder block, guiding exhaust power steering pump in place, to left cylinder
manifold studs into muffler inlet pipe connections. head and water pump. lighten bolts to 53. 1-71.9
Install remaining attaching bolts (longer bolts in N·m (40-53Ib-ft) and nut to 40.3-54.7 N·m (30-40
lower row of bolt holes). lighten all cylinder head Ib-ft). If equipped with air conditioning, attach A/C
attaching bolts in sequence shown in three steps: compressor to A I C compressor mounting
first to 95-108 N·m (70-80 Ib-ft), then to 136-149 bracket. lighten compressor mounting bolts to
N·m (100-110 Ib-ft), and finally to 176-189 N·m 23.3-31.7 N·m (18-23 Ib-ft). Connect service
(130-140 Ib-ft). When this procedure is used, valves and hoses to A I C compressor.
it is not necessary to tighten bolts after
extended operation. 12. Install generator mounting bracket to right
cylinder head.
13. Install generator and secondary air injection pump
to A/C compressor mounting bracket. Refer to
Specifications in this section for bolt torques.
14. Install drive belts. Refer to Section 03-05.
. 15. Fill and bleed cooling system. Refer to Section
03-03.
4. Clean and inspect push rods, one at a time. Clean
the oil passage in the push rods with a suitable
solvent, and blowout with compressed air. Connect battery ground cable.
5. Install push rods in original positions. Apply Ford 17. Start engine (6007) and check for leaks.
Multi-Purpose Grease DOAZ-19584-AA or 18. If equipped with air conditioning, evacuate A/C
equivalent meeting Ford specification compressor and partially charge system with
ESB-M 1C93-A to valve stem tips and push rod refrigerant. Refer to the Body, Chassis Manual,
ends. Section 12-00.
6. Lubricate and install the rocker arms. Refer to
Rocker Arm in this section. Make sure lower
ends of push rods remain seated in valve
tappets.

ALL RIGHTS RESERVED
03-01C-21 Engine, 7.5L MFI v-a 03-01C-21
7.5L AIC Compressor Mounting Bracket
VIEW A
A23627·A
Part Part
1 19B890 Air Conditioning Hose 4 3A674 Power Steering Pump
Assembly 5 388112 Stud
2 N806020-S2 Bolt, M8-1.25 x 123 6 2882 A / C Compressor Mounting
3 6754 Oil Level Indicator Tube Bracket

ALL RIGHTS RESERVED
03-01C-22 Engine, 7.5L MFI v-a 03-01C-22
Part Part
7 N800199-S8M Screw, M10-1.5x33 A - Tighten to 23.3-31.7 N·m
8 3A733 Power Steering Pump Pulley (18-23 Lb-Ft)
9 382802-S2 Nut, 3/8-16 B - Tighten to 40.3-54.7 N·m
391319-S2 Bolt, 7 116-14 x 5.25 (30-40 Lb-Ft)
10
11 56192-52 Bolt,1/2-13x3.75 C - Press Flush ± 0.254mm
(0.010 Inch)
12 6B209 Drive Belt Tensioner
13 8678 Belt Idler Pulley
D - Tighten to 53. 1-71.9 N·m
(40-53 Lb-Ft)
14 N605790-S2 Bolt, M8-1.25 x 40 E - Tighten to 68-92 N·m
15 19703 AIC Compressor (50-68 Lb-Ft)
(Continued)
7.5L Accessory Bracket, Right
FRONT OF ENGINE
~
V1EWZ
A16401-B
Part
1 10300 Generator
2 10145 Generator Adjusting Arm
(Continued)
ALL RIGHTS RESERVED
03-01C-23 Engine, 7.5L MFI V-8 03-01C-23
Part Part
3 390785-S36 Screw,3/8-16x 1.25- 14 56543-S36 Bolt, 3/8-16 x 1.75
Used with Small Frame 15 8509 Water Pump Pulley
Generator 16 8620 Drive Belt, 6k x 67.5 wI 0
4 56540-S36 Bolt, 3/8-16x 1.0 A/C and 6k x 68.6 with A/C
5 56542-S2 Bolt, 3/8-16 x 1.5 17 42998-S36 Bolt, 3/8-16 x 1.0
6 391319-S2 Bolt, 7 116-14 x 5.50 18 6312 Crankshaft Pulley
7 56564-S2 Bolt, 7 116-14 x 2.0 19 8620 Drive Belt, 6k x 49.5 -
8 391314-S2 Bolt, 3/8-16 x 5.25 Small and Medium Frame
9 56544-S36 Bolt, 3/8-16 x 2.0 Generator 6k x 50.5 -
10153 Generator Mounting Bracket Large Frame Alternator
10
11 N802493-S2 Screw and Washer, M6-1.0 x A - Tighten to 40.3-54.7 N·m
16 (30-40 Lb-Ft)
12 9B447 Secondary Air Injection B - Tighten to 53. 1-71.9 N·m
Pump Pulley (40-53 Lb-Ft)
13 9A486 Secondary Air Injection C - Tighten to 11.4-15.6 N·m
(9-11 Lb-Ft)
Pump
(Continued)
Crankshaft Pulley and/or Damper and/or 5. Remove front Woodruff key and slide crankshaft
Crankshaft Front Seal damper spacer off of crankshaft (6303).
Replacement of the crankshaft front seal (6700) 6. Place the Front Cover Seal Remover
is recommended whenever the engine front T70P-6B070-B onto the engine front cover over
cover (6019) is removed. the crankshaft front seal. lighten the two
through-bolts to force the seal puller under the
SPECIAL SERVICE TOOL(S) REQUIRED seal flange.
7. Alternately tighten the four puller bolts one half
turn at a time. Pull the crankshaft front seal from
Crankshaft Damper Remover T58P-6316-D the engine front cover.
Front Cover Seal Remover T70P-6B070-B
Crankshaft Seal Replacer / Cover T88T-670 1-A
Aligner
Crankshaft Damper and Sprocket T52L-6306-AEE
Replacer
Removal
(8146) to the radiator (8005).
2. Remove the fan bolts from the water pump hub.
Remove the fan blade (8600), fan clutch (8A616) FRONT COVER
SEAL REMOVER
and fan shroud. TOOL NO.
T70P-6B07o-B
3. Remove the drive belts (8620). Refer to Section
03-05. A6766-18

damper attaching bolt and washer. Remove
crankshaft vibration damper using Crankshaft
Damper Remover T58P-6316-D.

ALL RIGHTS RESERVED
03-01C-24 Engine, 7.5L MFI v-a 03-01C-24
Installation 6. Install the drive belts. Refer to Section 03-05.

1. Coat a new crankshaft front seal with Ford 7. Position the fan shroud over the water pump
Multi-Purpose Grease DOAZ-19584-AA or pulley (8509). Install the fan blade. Install the fan
equivalent meeting Ford specification shroud attaching screws.
ESB-M 1C93-A and place it onto the Crankshaft
Seal Replacer / Cover Aligner T88T-670 1-A.
Place the sleeve and crankshaft front seal onto
the end of the crankshaft and push it toward the
engine (6007) until the crankshaft front seal
starts into the engine front cover.
CRANKSHAFT SEAL
T8BT-6701-A I
(0
CRANKSHAFT DAMPER
AND SPROCKET
REPLACER
T62L-8308-AEE
A10077-B
A10352-e
2. Place the installation screw, washer, and nut onto

the end of the crankshaft. Thread the screw into
the crankshaft. Tighten the nut against the Water Pump
washer and installation sleeve to force the
crankshaft front seal into the engine front cover.
Removal
Remove the installatioh tool from the crankshaft. 1. Drain cooling system. Refer to Section 03-03.
3. Install crankshaft damper spacer on the inner 2. Remove drive belts (8620). Refer to Section
Woodruff key. Apply Gasket Maker 03-05.
E2AZ-19562-B or equivalent meeting Ford 3. Remove bolts attaching fan shroud (8146) to
specification WSK-M2G348-A5 to the front of the radiator (8005).
key on the crankshaft, and in the keyway inside
the crankshaft damper spacer, after installing 4. Remove fan blade (8600) from fan clutch
spacer. Install Woodruff key for crankshaft (8A616) and remove fan shroud.
vibration damper. 5. Remove fan clutch and water pump pulley (8509)
4. Apply Ford Multi-Purpose Grease from water pump (8501).
DOAZ-19584-AA or equivalent meeting Ford 6. Remove four bolts and one nut attaching A / C
specification ESB-M 1C93-A to the front seal compressor mounting bracket (2882) to cylinder
rubbing surface of the crankshaft vibration head (6049) and water pump. Do not remove air
damper inner hub to prevent damage to the A / C compressor (19703) or power steering
crankshaft front seal. Apply Ford Multi-Purpose pump (3A674) from A / C compressor mounting
Grease DOAZ-19584-AA or equivalent meeting bracket.
Ford specification ESB-M 1C93-A to the front of
7. Pull A / C compressor mounting bracket forward
the crankshaft for crankshaft vibration damper
to remove from stud on water pump.
installation.
8. Remove bolt attaching generator adjusting arm
5. Line up the crankshaft vibration damper keyway
(10145) to water pump. Remove four bolts
with the key on the crankshaft. Install the
attaching generator mounting bracket (10153) to
crankshaft vibration damper on crankshaft using
cylinder head, cylinder block (6010) and water
Crankshaft Damper and Sprocket Replacer
pump.
T52L-6306-AEE. Install the bolt and washer.
Tighten the bolt to 95-122 N·m (70-90 Ib-ft).
Install the crankshaft pulley.

ALL RIGHTS RESERVED
03-01C-25 Engine, 7.5L MFI v-a 03-01C-25
9. Remove remaining water pump attaching bolts 6. Install water pump pulley and fan clutch to water
and remove water pump from engine front cover pump hub with four bolts. Install fan blade to fan
(6019). Remove water pump cover (8508) from clutch with four bolts. Tighten water pump pulley,
water pump. Discard water pump housing gasket fan clutch hub bolts, and fan-to-fan clutch hub
(8507) and water pump cover gasket (8513). bolts to 16-24 N·m (12-18 Ib-ft). Install fan
shroud. .
7. Install drive belts. Refer to Section 03-05.
Section 03-03.
9. Start the engine (6007) and check for leaks.
Engine Front Cover

Front Cover Aligner T68P-6019-A
Crankshaft Damper and Sprocket T52L-6306-AEE
Replacer
Part
Removal
1 8501 Water Pump
Crankshaft front seal replacement is
recommended whenever the engine front cover
3 8600 Fan Blade (6019) has been removed.
4 8A616 Fan Clutch
5 380288-S2 Screw and Washer 1. Disconnect battery ground cable (14301). Drain
Assembly crankcase.
6 57632-S2 Screw and Washer 2. Drain cooling system. Refer to Section 03-03.
Assembly
3. Remove drive belts (8620). Refer to Section
A - Tighten to 16-24 N·m 03-05.
(12-18 Lb-Ft)
4. Remove bolts attaching fan shroud (8146) to
Installation radiator (8005).
1. Remove any gasket material from water pump, 5. Remove fan blade (8600) from fan clutch
cylinder front cover and separator plate mating (8A616) and remove fan shroud.
surfaces. 6. Remove fan clutch and water pump pulley (8509)
2. Position new water pump housing gasket and from water pump (8501).
water pump cover gasket coated on both sides 7. Disconnect upper radiator hose (8260) and lower
with Perfect Seal Sealing Compound radiator hose (8286) at engine (6007).
B5A-19554-A or equivalent meeting Ford Disconnect transmission oil cooler lines at
specification ESE-M4G 115-A water-resistance radiator.
sealer.
8. Remove upper radiator support bracket and
3. Position water pump and water pump cover onto remove radiator.
engine front cover. Install bolts and tighten to
16-24 N·m (12-18Ib-ft). 9. Remove generator pivot and attaching bolts.
Remove generator (GEN)( 10300) from generator
4. Install generator mounting bracket to cylinder mounting bracket (10153) and generator
head, cylinder block and water pump with four adjusting arm (10145).
attaching bolts. Install generator adjusting arm to
water pump with one attaching bolt. Tighten 10. Remove two bolts attaching generator adjusting
7 I 16-inch bolts to 53.1-71.9 N·m (40-53Ib-ft) arm to water pump and generator mounting
and 3/8-inch bolts to 40.3-54.7 N·m (30-40 Ib-ft). bracket and remove generator adjusting arm.
5. Position A/C compressor mounting bracket over 11. Remove air pump pivot and attaching bolts.
water pump stud and secure to cylinder head with Remove secondary air injection pump (AIR
four bolts tightened to 53.1-71.9 N·m (40-53Ib-ft) pump)(9A486) from generator mounting bracket.
"and secure nut to water pump to 40.3-54.7 N·m
(30-40Ib-ft).

ALL RIGHTS RESERVED
03-01C-26 Engine, 7.5L MFI v-a 03-01C-26
12. Remove four bolts attaching generator mounting

bracket to cylinder head (6049), cylinder block
(6010) and water pump, and remove generator
mounting bracket.
13. Remove power steering pump pulley (3A733)
from power steering pump (3A674).
14. Remove power steering lines from power steering
pump. Remove four bolts attaching power
steering pump to A I C compressor mounting
bracket (2882) and remove power steering pump
from A I C compressor mounting bracket.
15. Remove four bolts attaching A I C compressor
(19703) to A/C compressor mounting bracket.
Remove four bolts and one nut attaching A I C
compressor mounting bracket to cylinder head
and water pump. Remove A I C compressor
mounting bracket from engine.
crankshaft vibration damper (6316).
17. Remove bolt and washer attaching crankshaft
vibration damper. Remove crankshaft vibration
damper using Crankshaft Damper Remover
T58P-6316-D or Rotunda Gear and Pulley Puller
014-00293 or equivalent. Remove Woodruff key
and crankshaft damper spacer from crankshaft
(6303).
Part
A17843-B Item Number Description
1 6019 Engine Front Cover
18. Loosen water bypass tube or hose (8548) at 2 6710 Oil Pan Gasket
water pump. Disconnect heater return hose at
3 391496-52 Bolt
water pump.
4 6675 Oil Pan
19. NOTE: If the original gasket was not damaged 5 6010 Cylinder Block
from front cover removal, it may be reused. If 6 E2AZ-19562-B Gasket Maker (2 Places)
damage is evident, the oil pan gasket (6710)
7 E2AZ-19562-B Gasket Maker (4 Places)
must be replaced in its entirety.
Remove bolts attaching engine front cover to (8-12 Lb-Ft)
cylinder block. Remove engine front cover and
water pump as an assembly. Discard engine front 20. If new engine front cover is to be installed, remove
cover gasket (6020) and oil pan gasket. water pump and install it and a new water pump
housing gasket (8507) on the new engine front
cover.
21. Check timing chain deflection. Refer to Section
03-00.
Installation
1. Replace crankshaft front seal (6700). Refer to
Crankshaft Front Pulley and lor Damper and lor
Crankshaft Front Seal in this section.
ALL RIGHTS RESERVED
03·01C·27 Engine, 7.5L MFI v·a 03·01C·27
2. Clean sealing surfaces of engine front cover and 8. While pushing in on Front Cover Aligner
~ cylinder block. Also, clean oil pan gasket sealing T68P-6019-A, tighten the oil pan-to-engine front
surfaces of any oil or debris. cover attaching bolts to 8-12 N·m (70-105Ib-in).
3. Coat the gasket surfaces of the cylinder block Remove alignment tool. lighten the engine front
and engine front cover with Perfect Seal Sealing cover-to-cylinder block attaching screws to
Compound B5A-19554-A or equivalent meeting 16-24 N·m (12-18 Ib-ft).
Ford specification ESR-M 18P2-A oil resistant 9. Apply Ford Multi-Purpose Grease
sealer and position a new engine front cover DOAZ-19584-AA or equivalent meeting Ford
gasket on the cylinder block. specification ESB-M 1C93-A to front of crankshaft
4. Apply Gasket Maker E2AZ-19562-B or for crankshaft vibration damper installation.
equivalent meeting Ford specification 10. Install crankshaft damper hub (6359) on the inner
WSK-M2G348-A5 along the cylinder block pan Woodruff key.
gasket junction where the engine front cover 11. Apply Gasket Maker E2AZ-19562-B or
contacts the oil pan gasket. equivalent meeting Ford specification
5. Position the engine front cover onto the cylinder WSK-M2G348-A5 to the front of the key on the
block. Use care when installing the engine front crankshaft, and in the keyway inside the
cover to avoid seal damage or possible crankshaft damper spacer, after installing
mislocation. spacer.
6. Install Front Cover Aligner T68P-60 19-A into 12. Position crankshaft damper Woodruff key and
proper position. It may be necessary to force the install crankshaft vibration damper using
engine front cover downward in a manner to Crankshaft Damper and Sprocket Replacer
slightly compress the oil pan gasket. This T52L-6306-AEE. Install crankshaft vibration
operation can be facilitated by using a suitable damper attaching bolt and washer. lighten to
tool at the attaching bolt hole locations. 95-122 N·m (70-90 Ib-ft).
CRANKSHAFT DAMPER
AND SPROCKET
REPLACER
T52L-6306-AEE
A10077·B
13. Install crankshaft pulley to crankshaft vibration

damper. lighten four bolts to 54-71 N·m (40-53
FRONT COVER Ib-ft).
ALIGNER TOOL
T68P-6019-A 14. Install A / C compressor mounting bracket to
cylinder head using four bolts. Tighten to
53.1-71.9 N·m (40-53Ib-ft). Tighten nut to water
7. Coat the threads of the attaching bolts with Pipe
pump stud to 40.3-54.7 N·m (30-40 Ib-ft).
Sealant with Teflon@ D8AZ-19554-A or
equivalent oil-resistant sealer meeting Ford 15. Attach A / C compressor to A / C compressor
specification WSK-M2G350-A2 and install the mounting bracket with four bolts and tighten to
screws. 23.3-31.7 N·m (18-23Ib-ft).
ALL RIGHTS RESERVED
03-01C-28 Engine, 7.5L MFI V-8 03-01C-28
16. Attach power steering pump lines to power Timing Chain and Sprockets
steering pump. Press power steering pump pulley
onto power steering pump. Make sure front SPECIAL SERVICE TOOL(S) REQUIRED
surface of pulley hub is flush with end of pump
shaft. Description Tool Number
17. Attach generator mounting bracket to cylinder Crankshaft Damper Remover T58P-6316-D
head, cylinder block and water pump with four Front Cover Aligner T68P-6019-A
bolts. lighten 3 I 8-inch bolts to 40.3-54.7 N·m Crankshaft Damper and Sprocket T52L-6306-AEE
(30-40 Ib-ft) and 7 I 16-inch bolts to 53. 1-71.9 Replacer
N·m (40-53Ib-ft).
18. Install secondary air injection pump to generator
mounting bracket with two bolts. lighten to
40.3-54.7 N·m (30-40 Ib-ft). Install secondary air Removal
injection pump pulley. lighten screws to Crankshaft front seal replacement is
11.4-15.6 N·m (9-11Ib-ft). recommended whenever the engine front cover
19. Install generator adjusting arm to generator (6019) has been removed.
mounting bracket and water pump with two bolts. 1. Disconnect battery ground cable (14301). Drain
lighten to 40.3-54.7 N·m (30-40 Ib-ft). crankcase.
20. Install generator to generator mounting bracket 2. Drain cooling system. Refer to Section 03-03.
using two bolts. Do not tighten bolts until drive
3. Remove drive belts (8620). Refer to Section
belt has been tensioned.
03-05.
21. Install drive belts and adjust drive belt tension to
4. Remove bolts attaching fan shroud (8146) to
specifications. Refer to Section 03-05.
radiator (8005).
22. Position radiator to lower support. Position upper
5. Remove fan blade (8600) from fan clutch
radiator support bracket to radiator, and install
(8A616) and remove fan shroud.
attaching bolts. Connect upper radiator hose and
lower radiator hose at engine. Connect 6. Remove fan clutch and water pump pulley (8509)
transmission oil cooler lines. from water pump (8501).
23. Place fan blade inside fan shroud and set in 7. Disconnect upper radiator hose (8260) and lower
position in vehicle. Position the fan blade and fan radiator hose (8286) at engine (6007).
clutch on the water pump pulley. Install and Disconnect transmission oil cooler lines at
tighten the attaching bolts to 16-24 N·m (12-18 radiator.
Ib-ft). Install screws attaching fan shroud to 8. Remove upper radiator support bracket and
radiator. remove radiator.
24. The crankcase oil should be drained and refilled 9. Remove generator pivot and attaching bolts.
with the proper grade and quantity of engine oil Remove generator (GEN)( 10300) from generator
before starting the engine. mounting bracket ( 10153) and generator
25. Install heater return hose to water pump. Fill and adjusting arm (10145).
bleed the cooling system. Refer to Section 03-03. 10. Remove two bolts attaching generator adjusting
26. NOTE: When the battery has been disconnected arm to water pump and generator mounting
and reconnected, some abnormal drive bracket and remove generator adjusting arm.
symptoms may occur while the powertrain 11. Remove air pump pivot and attaching bolts.
control module (PCM)( 12A650) relearns its Remove secondary air injection pump (AIR
adaptive strategy. The vehicle may need to be pump)(9A486) from generator mounting bracket.
12. Remove four bolts attaching generator mounting
Connect battery ground cable. bracket to cylinder head (6049), cylinder block
27. Run engine at fast idle and check for coolant and (6010) and water pump, and remove generator
oil leaks. Adjust ignition timing to specification mounting bracket.
listed on the Vehicle Emission Control Information 13. Remove power steering pump pulley (3A733)
(VECI) decal. from power steering pump (3A674).
14. Remove power steering lines from power steering
pump. Remove four bolts attaching power
steering pump to A I C compressor mounting
bracket (2882) and remove power steering pump
from A/C compressor mounting bracket.
ALL RIGHTS RESERVED
03-01C-29 Engine, 7.5L MFI v-a 03-01C-29
15. Remove four bolts attaching A / C compressor

( 19703) to A / C compressor mounting bracket.
Remove four bolts and one nut attaching A / C
compressor mounting bracket to cylinder head
and water pump. Remove A / C compressor
mounting bracket from engine.
crankshaft vibration damper (6316).
17. Remove bolt and washer attaching crankshaft
vibration damper. Remove crankshaft vibration o
damper using Crankshaft Damper Remover
T58P-6316-D or Rotunda Gear and Pulley Puller
014-00293 or equivalent. Remove Woodruff key
and crankshaft damper spacer from crankshaft
o
TIMING
(6303). MARKS
A10737·1A
23. Remove camshaft sprocket bolt and camshaft

sprocket washer (6278). Discard camshaft
sprocket bolt. Slide timing chain, camshaft
sprocket and crankshaft sprocket forward, and
remove as an assembly.
A17843-B
18. Loosen water bypass tube or hose (8548) at

water pump. Disconnect heater return hose at
water pump.
19. Remove bolts attaching engine front cover to
cylinder block. Remove engine front cover and
water pump as an assembly. Discard engine front
cover gasket (6020) and oil pan gasket (6710).
Using a thin-blade knife, cut the oil pan gasket
flush with cylinder block face separating the
engine front cover from the cylinder block.
20. If new engine front cover is to be installed, remove
water pump and install it and a new water pump
housing gasket (8507) on the new engine front
cover.
21. Check timing chain deflection. Refer to Section
03-00.
22. If the timing chain, camshaft sprocket (6256) and
crankshaft sprocket (6306) are to be removed,
crank the engine until timing marks on camshaft
sprocket and crankshaft sprocket are as shown. A10738·1A
24. Refer to Section 03-00 for cleaning and

inspection procedures.
1995 F-:150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain July 1994
ALL RIGHTS RESERVED
03-01C-30 Engine, 7.5L MFI v-a 03-01C-30
Installation
1. Assemble the timing chain, camshaft sprocket
and crankshaft sprocket so sprocket timing
marks align with each other as shown under
Removal. Install the timing chain, camshaft
sprocket and crankshaft sprocket as an
assembly to crankshaft and camshaft (6250). If a
new timing chain is to be installed, submerge
timing chain in a container of recommended
quality engine oil. Verify proper alignment of
timing marks after installation.
2. Install new camshaft sprocket bolt and camshaft
sprocket washer. Tighten bolt to 54-68 N·m
(40-50 Ib-ft). Lubricate timing chain with
recommended quality engine oil.
3. Replace crankshaft front seal (6700). Refer to
Crankshaft Pulley and / or Damper and / or
Crankshaft Seal in this section.
4. Clean sealing surfaces of engine front cover and
cylinder block. Also, clean oil pan gasket sealing
~'
surfaces of any oil or debris.
5. Coat the gasket surfaces of the cylinder block
and engine front cover with Perfect Seal Sealing
Compound B5A-19554-A or equivalent oil
resistant sealer meeting Ford specification FRONT COVER
ALIGNER TOOL
ESR-M 18P2-A and position a new engine front T68P-6019-A
cover gasket on the cylinder block.
6. Apply Gasket Maker E2AZ-19562-B or 9. Coat the threads of the attaching bolts with Pipe
equivalent meeting Ford specification Sealant with Teflon@ D8AZ-19554-A or
WSK-M2G348-A5 along the cylinder block pan equivalent oil-resistant sealer meeting Ford
gasket junction where the engine front cover specification WSK-M2G350-A2 and install the
contacts the oil pan gasket. screws.
7. Position the engine front cover onto the cylinder 10. While pushing in on Front Cover Aligner
block. Use care when installing the engine front T68P-6019-A, tighten the oil pan-to-engine front
cover to avoid seal damage or possible cover attaching bolts to 8-12 N·m (70-105Ib-in).
mislocation. Remove alignment tool. Tighten the engine front
8. Install Front Cover Aligner T68P-6019-A into cover-to-cylinder block attaching screws to
proper position. It may be necessary to force the 16-24 N·m (12-18Ib-ft).
engine front cover downward in a manner to 11. Apply Ford Multi-Purpose Grease
slightly compress the oil pan gasket. This DOAZ-19584-AA or equivalent meeting Ford
operation can be facilitated by using a suitable specification ESR-M 1C 159-A to front of
tool at the attaching bolt hole locations. crankshaft for crankshaft vibration damper
installation.
12. Install crankshaft damper hub (6359) on the inner
Woodruff key.
13. Apply Gasket Maker E2AZ-19562-B or
WSK-M2G348-A5 to the front of the key on the
crankshaft, and in the keyway inside the
crankshaft damper spacer, after installing
spacer.
ALL RIGHTS RESERVED
03-01C-31 Engine, 7.5L MFI v-a 03-01C-31
14. Position crankshaft damper Woodruff key and 21. Install generator adjusting arm to generator
install crankshaft vibration damper using mounting bracket and water pump with two bolts.
Crankshaft Damper and Sprocket Replacer Tighten to 40.3-54.7 N·m (30-40 Ib-ft).
T52L-6306-AEE. Install crankshaft vibration 22. Install generator to generator mounting bracket
damper attaching bolt and washer. Tighten to using two bolts. Do not tighten bolts until drive
95-122 N·m (70-90 Ib-ft). belt has been tensioned.
23. Install drive belts and adjust drive belt tension to
specifications. Refer to Section 03-05.
24. Position radiator to lower support. Position upper
radiator support bracket to radiator, and install
attaching bolts. Connect upper radiator hose and
lower radiator hose at engine. Connect
transmission oil cooler lines.
25. Place fan blade inside fan shroud and set in
position in vehicle. Position the fan blade and fan
clutch on the water pump pulley. Install and
tighten the attaching bolts to 16-24 N·m (12-18
Ib-ft). Install screws attaching fan shroud to
radiator.
26. The crankcase oil should be drained and refilled
with the proper grade and quantity of engine oil
before starting the engine.
CRANKSHAFT DAMPER 27. Install heater return hose to water pump. Fill and
AND SPROCKET bleed the cooling system. Refer to Section 03-03.
REPLACER
T52L-6306-AEE NOTE: When the battery has been disconnected and
reconnected, some abnormal drive symptoms may
A10077·B occur while the powertrain control module
(PCM)( 12A650) relearns its adaptive strategy. The
15. Install crankshaft pulley to crankshaft vibration vehicle may need to be driven 10 miles or more to
damper. Tighten four bolts to 54-71 N·m (40-53 relearn the strategy.
Ib-ft).
28. Connect battery ground cable.
16. Install A/C compressor mounting bracket to
cylinder head using four bolts. Tighten to 29. Run engine at fast idle and check for coolant and
53.1-71.9 N·m (40-53Ib-ft). Tighten nut to water oil leaks. Adjust ignition timing to specification
pump stud to 40.3-54.7 N·m (30-40 Ib-ft). listed on the Vehicle Emission Control Information
(VECI) decal.
17. Attach A I C compressor to A I C compressor
mounting bracket with four bolts and tighten to
23.3-31.7 N·m (18-23 Ib-ft).
18. Attach power steering pump lines to power Camshaft
steering pump. Press power steering pump pulley
onto power steering pump. Make sure front Removal
surface of pulley hub is flush with end of pump 1. Drain radiator (8005) and remove. Refer to
shaft. Section 03-03.
19. Attach generator mounting bracket to cylinder
head, cylinder block and water pump with four
bolts. Tighten 3 I 8-inch bolts to 40.3-54.7 N·m
(30-40 Ib-ft) and 7 I 16-inch bolts to 53.1-71.9
N·m (40-53Ib-ft).
20. Install secondary air injection pump to generator
mounting bracket with two bolts. lighten to
40.3-54.7 N·m (30-40 Ib-ft). Install secondary air
injection pump pulley. Tighten screws to
11.4-15.6 N·m (9-11 Ib-ft).
ALL RIGHTS RESERVED
03-01C-32 Engine, 7.5L MFI v-a 03-01C-32
2. Remove engine front cover (6019), timing chain,

camshaft sprocket (6256) and crankshaft
sprocket (6306). Refer to Timing Chain and
Sprockets in this section. Check timing chain
deflection before removal. Refer to Section
03-00.
6. Remove the valve tappets (6500) with a magnet

and place them in a rack in sequence. Rotate the
valve tappets back and forth to loosen them from
gum or varnish deposits.
7. Remove the bolts attaching the A I C condenser
core (19712) to the chassis, if so equipped.
Carefully rest the condenser on the left fender.
Secure it in this position.
8. Remove the radiator inner grille (8150).
9. Remove the camshaft thrust plate attaching
bolts, and carefully remove the camshaft (6250)
A18723-B from the front of engine (6007). Do not damage
the camshaft bearings (6261) by nicking
Part them with the camshaft lobes.
Item Number Description Refer to Section 03-00 for cleaning and
1 6261 Camshaft Bearing inspection procedures, and repair as required.
Cover Installation
3 6250 Camshaft 1. Oil the camshaft journals and apply Ford
4 42910 Bolt, 1/4-20x 1/2, Multi-Purpose Grease DOAZ-19584-AA or
Self-Locking equivalent meeting Ford specification
5 6268 Timing Chain ESB-M 1C93-A to the camshaft lobes. Carefully
6 6278 Camshaft Sprocket Washer slide camshaft into position. Avoid nicking the
7 43001 Bolt, 3/8-16x 1.38 camshaft bearings with the camshaft lobes.
8 6256 Camshaft Sprocket 2. Install camshaft thrust plate (6269). Tighten bolts
9 6269 Camshaft Thrust Plate to 11-15 N·m (90-135Ib-in). Check camshaft end
A - Tighten to 11-15 N·m play following procedure in Section 03-00. If end
(90-135 Lb-In) play is excessive, replace the camshaft thrust
B - Tighten to 54-68 N·m plate.
(40-50 Lb-Ft) 3. Install timing chain, camshaft sprocket,
crankshaft sprocket, new bolt, camshaft
3. Remove the upper and lower intake manifolds
sprocket washer (6278) and engine front cover.
(9424). Refer to Intake Manifold, Upper and
Refer to Timing Chain and Sprockets in this
Lower in this section.
section.
4. Remove distributor. Refer to Section 03-07A.
4. Position the radiator in the vehicle and install the
5. Remove valve covers (6582). Back off all rocker upper radiator support bracket to secure
arm seat bolts, turn rocker arms (6564) radiator. Connect the lower radiator hose (8286)
sideways, and remove the push rods (6565) and upper radiator hose (8260).
keeping them in sequence.
5. Install the radiator inner grille.
6. Install A/C condenser core.

ALL RIGHTS RESERVED
03-01C-33 Engine, 7.5L MFI v-a 03-01C-33
~
7. Clean the valve tappets externally. Lubricate the 21. Adjust transmission linkage, if necessary. Refer
valve tappets and valve tappet bores with to Section 07-01A or 07-01B.lnstall the engine
specified engine oil before installing them. air cleaner (ACL)(9600) and air cleaner outlet
Lubricate the push rod ends with Ford tube (98659).
ESR-M 1C 159-A. Install the valve tappets and
push rods in their original positions. Exhaust Manifolds
8. Install upper and lower intake manifolds. Refer to
Intake Manifold, Upper and Lower in this section. SPECIAL SERVICE TOOL(S) REQUIRED
9. Rotate the crankshaft vibration damper (6316) Description Tool Number
until No. 1 piston (6108) is at TDC at the end of
compression stroke. Install the distributor
(12127) following the procedure in Section
03-07A. Removal
10. Apply Ford Multi-Purpose Grease 1. Remove oil level indicator tube (6754) from left
DOAZ-19584-AA or equivalent meeting Ford exhaust manifold (9431).
specification ESB-M1C93-A to valve stem tips. 2. Remove spark plug heat shield (12A406).
Position rocker arms over push rods and tighten 3. Remove distributor to spark plug wires (12286)
bolts. Refer to Rocker Arm in this section. Adjust using Spark Plug Wire Remover T74P-6666-A.
valve clearance if necessary. Refer to
Adjustments in this section.
11. Clean the valve covers and cylinder head sealing
surfaces. Position new valve cover gasket
(6584), if required, in cover seal groove. Make
sure that the valve cover gasket tang is secured
in the notch of the valve cover.
12. PO'sition valve cover on the cylinder head (6049)
and tighten the four valve cover bolt and washer
assemblies to 12-15 N·m (9-11 Ib-ft), starting at
the rearmost bolt and working forward.
13. Connect heater hose at intake manifold and at
water pump (8501).
TWIST AND PULL
14. Install the accelerator linkage. Install the speed
control linkage, if so equipped. B3498·E
15. Connect engine vacuum lines to their original 4. Disconnect EGR valve to exhaust manifold tube
outlets on the fittings of the upper and lower (90477) on left exhaust manifold.
intake manifolds. 5. Disconnect muffler inlet pipe.
16. Connect positive crankcase ventilation valve 6. Remove attaching bolts. Remove right exhaust
(PCV valve)(6A666) and crankcase vent manifold (9430) or left exhaust manifold.
connector and hose (6C324) to right valve cover.
17. Install the distributor cap (12106) and connect • Inspect the cylinder head joining flanges of the
the ignition coil (12029) and distributor to spark right exhaust manifold or left exhaust
plug wires (12286). manifoldfor evidence of exhaust gas leaks.
18. Install water pump pulley (8509) and fan clutch • Inspect the right exhaust manifold or left
(8A616) to water pump hub with four bolts. Install exhaust manifold for cracks, damaged sealing
fan blade (8600) to fan clutch with four bolts. surfaces, or other wear or damage that would
Tighten water pump pulley, fan clutch hub bolts, make them unfit for further service.
and fan-to-fan clutch hub bolts to 16-24 N·m Installation
(12-18Ib-ft).lnstall fan shroud (8146). Install
drive belt (8620) according to instructions on 1. Clean mating surfaces of right exhaust manifold
decal on upper radiator support bracket. or left exhaust manifold and cylinder head
(6049). Clean mounting flange of right exhaust
19. Fill and bleed the cooling system. Refer to manifold or left exhaust manifold and inlet pipe(s).
Section 03-03. Fill and bleed power steering Apply light film of Premium Long-Life Grease
reservoir. Run engine at fast idle and check for XG-1-C or -K or equivalent meeting Ford
leaks. specification ESA-M 1C75-B to right exhaust
20. Adjust the ignition timing to specifications listed manifold or left exhaust manifold.
on the engine decal.
1995 F-150, F-250, F-350, Bronco, F-Super Du~y Powertrain, Drivetrain July 1994
-,
ALL RIGHTS RESERVED
03-01C-34 Engine, 7.5L MFI v-a 03-01C-34
2. Position right exhaust manifold or left exhaust 4. Connect EGR valve to exhaust manifold tube to
manifold on cylinder head. Install attaching bolts left exhaust manifold, if removed. Tighten nut to
and washers, starting at fourth bolt hole from 34-65 N·m (25-48 Ib-ft).
front of each right exhaust manifold or left 5. Install spark plug heat shield and distributor to
exhaust manifold. lighten bolts to 52-65 N·m spark plug wires.
(38-48 Ib-ft), working from center right to both
ends. 6. Install oil level indicator tube to left exhaust
manifold, if removed. Tighten nut to 13-24 N·m
3. Position inlet pipes to right exhaust manifold or (10-18 Ib-ft).
left exhaust manifold. Install attaching nuts and
tighten to 39-49 N·m (25-36 Ib-ft). 7. Start engine (6007) and check for exhaust leaks.
7.5L Exhaust Manifold Installation
.,
FRONT OF ENGINE
FRONT OF
ENGINE
~
RIGHT SIDE
LEFT SIDE A16403-C
Part Part
1 391334-5101 3/8-16-16 x 2.64 Hex 9 391335-S 101 3/8-16 x 3.77 Hex Shoulder
Shoulder Pilot Stud Flange Stud (2 Places)
(3 Places) 10 33771 3/8-16 Nut (3 Places)
2 391335-S101 3/8-16-16 x 3.77 Hex 11 12A406 Spark Plug Heat Shield
Shoulder Pilot Stud 12 391333-S 10 1 3/8-16 x 2.57 Hex Flange
(2 Places) Pilot Bolt (2 Places)
3 33771 3/8-16 Nut (This Location 13 391334-S 101 3/8-16-16 x 2.64 Hex
Only) Shoulder Pilot Stud
4 12A406 Spark Plug Heat Shield (4 Places)
5 391333-S 101 3/8-16 x 2.57 Hex Flange 14 9431 Exhaust Manifold - Left
Pilot Bolt (2 Places) 15 6049 Cylinder Head - Left
6 391332-S101 3/8-16 x 1.44 Hex Flange A - Tighten to 52-65 N·m
Pilot Bolt (1 Place) (38-48 Lb-Ft)
7 9430 Exhaust Manifold - Right B - Tighten to 13-24 N·m
8 6049 Cylinder Head - Right (10-18 Lb-Ft)
(Continued)
ALL RIGHTS RESERVED
03 01C-35
a
Engine, 7.5L MFI v-a 03-01C-35
Oil Pan and/or Oil Pump Screen Cover and 14. Remove the muffler inlet pipe assembly.
Tube Disconnect the manual and kickdown linkage
from the transmission (7003).
Removal
15. Remove the driveshaft (4602) and coupling shaft
1. Disconnect the battery ground cable (14301). assembly. Remove the oil filler tube (7A228)
2. Drain the cooling system. Refer to Section 03-03. assembly.
3. Remove the engine air cleaner (ACL)(9600) and 16. Remove the oil level dipstick (6750) and oil level
air cleaner outlet tube (98659). indicator tube (6754) from the oil pan (6675).
Refer to Oil Level Indicator Tube in this section.
4. Remove fan shroud (8146), fan blade (8600), and Place a transmission jack under the engine oil
water pump pulley (8509). pan. Insert a wood block between the jack
5. Disconnect throttle body linkage and wiring. surface and the oil pan. Jack the engine (6007)
6. Disconnect vacuum lines from upper intake upward, pivoting about the rear mount until the
manifold (9424) and lower intake manifolds. Tag transmission contacts the floor pan. Then, block
the engine in position at the engine front supports.
lines to aid in reassembly.
The engine must remain centralized to obtain the
7. Perform fuel system pre-service. Refer to Section maximum height. The engine must be raised
03-04C. Using Spring Lock Coupling Disconnect 102mm (four inches) at the engine front supports
Tool D87L-9280-A and -8 or equivalent, to remove the oil pan.
disconnect fuel supply and return lines.
17. Remove the oil pan retaining bolts and remove oil
8. Disconnect the upper radiator hose (8260) and pan flange reinforcement (6A674). Lower the oil
lower radiator hoses (8286). pan. Remove the oil pump and pickup tube
9. Disconnect the two transmission oil cooler lines attachments. Drop the oil pump (6600) and oil
at the radiator (8005). pump screen cover and tube (6622) into the oil
pan. Remove the oil pan rearward from the
10. Remove the power steering pump (3A674) and vehicle.
position out of the way.
11. Disconnect the front engine support insulators
Installation
(6038) from the front engine support brackets. 1. Clean the oil pan gasket surface at the cylinder
block (6010). Clean the oil pan assembly, the oil .
12. If so equipped, rotate air conditioner lines (at rear
pump screen cover and tube. Prime the oil pump
of A I C compressor (19703» down to clear the
by filling the inlet opening with oil and rotate the oil
dash. Remove A/C compressor without
pump intermediate shaft (6A618) until oil
disconnecting hoses and set out of the way.
emerges from the outlet opening.
13. Raise the vehicle on a hoist, drain the crankcase,
and remove the oil bypass filter (6714).
ALL RIGHTS RESERVED
03-01C-36 Engine, 7.5L MFI v-a 03-01C-36
2. Lightly apply Gasket Maker E2AZ-19562-B or

equivalent meeting Ford specification Part
WSK-M2G348-A5 to the cylinder block surface Item Number Description
and a 6mm (1 I 4 inch) diameter bead to engine 4 6675 Oil Pan
front cover (60 19) and rear main bearing cap as 5 E2AZ-19562-B Gasket Maker (2 Places)
shown. Also apply a bead at the parting line of 6 E2AZ-19562-B Gasket Maker (4 Places)
engine front cover and cylinder block. Position the
one-piece silicone oil pan gasket (6710) to the
(8-12 Lb-Ft)
cylinder block and press lightly until oil pan
gasket sticks to surface. Position the oil pan with 3. Position the oil pan to the cylinder block position
oil pump and oil pump screen cover and tube to oil pan flange reinforcement and install the
the chassis. Install the oil pump and oil pump attaching bolts. Tighten 114-inch bolts to 11-16
screen cover and tube to the cylinder block. N·m (8-12 Ib-ft).
Tighten attaching bolts to 30-43 N·m (22-32 Ib-ft).
4. Place jack under engine and raise engine enough
to remove blocks.
5. Lower engine and remove jack.
6. Install the oil level indicator tube and oil level
dipstick. Refer to Oil Level Indicator Tube in this
section.
7. Reposition the air conditioner lines, if so
equipped. If removed, reinstall AIC compressor.
8. Install the front engine support insulator-to-front
engine support bracket retaining nuts. Tighten
nuts to 96-127 N·m (71-84 Ib-ft). Connect the
manual kickdown linkage at the transmission.
Install the driveshaft and coupling shaft assembly,
and the muffler inlet pipe assembly.
9. Clean the oil filter mounting surface and install the
oil bypass filter.
1O. Lower the vehicle from the hoist.
11. Install the radiator and connect the two
transmission oil cooler lines.
12. Install the fan blade and fan shroud, and then
connect the lower radiator hose and upper
radiator hose.
13. Connect vacuum lines to upper and lower intake
manifold.
14. Connect the throttle and transmission linkage at
the throttle body (9E926).
15. Install the power steering pump and drive belt
(8620).
16. Install the engine air cleaner and air cleaner outlet
tube.
Section 03-03.
Part driven 10 miles or more to relearn the strategy.
Item Number Description Connect the battery ground cable.
1 6019 Engine Front Cover 19. Fill the crankcase with engine oil. Start the engine
2 6710 Oil Pan Gasket and check for leaks.
3 391496-82 Bolt
(Continued)
ALL RIGHTS RESERVED
03-01C-37 Engine, 7.5L MFI v-a 03-01C-37
Oil Pump Installation

To remove and install the oil pump (6600), refer to Oil 1. To install upper half of crankshaft main bearing or
Pan and / or Oil Pump Screen Cover and Tube in this crankshaft thrust main bearing, place plain end of
section. The oil pump and oil pan (6675) must be crankshaft main bearing or crankshaft thrust
removed together. main bearing over crankshaft on locking tang side
of cylinder block (6010) and partially install
crankshaft main bearing or crankshaft thrust
main bearing so Main Bearing Insert Tool
Crankshaft Main Bearings TOOL-6331-E or equivalent can be inserted into
oil hole in crankshaft. With Main Bearing Insert
Crankshaft main bearings (6333), crankshaft thrust Tool TOOL-6331-E or equivalent in oil hole, rotate
main bearings (6337) and connecting rod bearings the crankshaft in the opposite direction of engine
(6211) are selective fits. Refer to Section 03-00. rotation until the crankshaft main bearing or
Removal crankshaft thrust main bearing seats itself.
Remove the tool.
1. Drain the crankcase. Remove the oil level
dipstick (6750). Remove the oil pan (6675), oil 2. Fit the crankshaft main bearings or crankshaft
pump (6600) and related parts. Refer to Oil Pan thrust main bearings with Plastigage@. Refer to
and / or Oil Pump Screen Cover and Tube in this Section 03-00.
section. 3. After the crankshaft main bearing or crankshaft
2. Replace one crankshaft main bearing or thrust main bearing has been fitted, apply light
crankshaft thrust main bearing at a time, leaving coat of specified engine oil to journal and
other crankshaft main bearings securely crankshaft main bearings or crankshaft thrust
fastened. Remove the crankshaft main bearing main bearings. Install the crankshaft main bearing
cap to which new crankshaft main bearings or cap. Tighten the crankshaft main bearing cap
crankshaft thrust main bearings are to be bolts to 129-142 N·m (95-105Ib-ft).
installed. 4. Repeat the procedure for remaining crankshaft
3. Insert Main Bearing Insert Tool TOOL-6331-E or main bearings or crankshaft thrust main bearings
equivalent in oil hole in crankshaft (6303). requiring replacement.
4. Rotate the crankshaft in the direction of engine 5. If the rear crankshaft main bearing is to be
rotation to force crankshaft main bearing or replaced, remove the rear crankshaft main
crankshaft thrust main bearing out of block. bearing cap. Remove and discard the crankshaft
rear oil seal (6701).
5. Clean the crankshaft journals. Inspect journals
and thrust faces (crankshaft thrust main bearing) 6. Clean rear journal oil seal groove and mating
for nicks, burrs or bearing pickup that would surfaces of cylinder block and rear crankshaft
cause premature bearing wear. main bearing cap.
7. Install the new crankshaft rear oil seal. Refer to
Crankshaft Rear Oil Seal in this section.
8. Refer to Crankshaft Rear Oil Seal in this section
for procedure used in sealing the rear crankshaft
main bearing cap. After sealing, install the rear
crankshaft main bearing cap. Tighten rear
crankshaft main bearing cap bolts 129-142 N·m
(95-105Ib-ft).
9. If thrust bearing cap (No.3) has been removed,
install as follows:
Install the thrust bearing cap with bolts
finger-tight. Pry the crankshaft forward against
the thrust surface of upper half of crankshaft
thrust main bearing. Hold the crankshaft forward
and pry crankshaft thrust main bearing cap to
rear. This aligns thrust surfaces of both halves of
CRANKSHAFT
JOURNAL crankshaft thrust main bearing. Retain forward
A10363-B pressure on crankshaft. Tighten cap bolts to
129-142 N·m (95-105Ib-ft).
ALL RIGHTS RESERVED
03-01C-38 Engine, 7.5L MFI v-a 03-01C-38
Tightening Crankshaft Thrust Main Bearing Cap 2. Remove any ridge and / or deposits from upper
end of cylinder bores as follows:
Turn the crankshaft (6303) until the piston (6108)
to be removed is at bottom of its travel. Place a
cloth on top of the piston to collect cuttings.
Remove any ridge and / or deposits from the
upper end of the cylinder bore. Remove the
cylinder ridge with a ridge cutter. Follow
instructions furnished by tool manufacturer.
Never cut into ring travel area in excess of
0.79mm (1/32 inch) when removing ridges.
Repeat the procedure at the remaining cylinders.
3. Make sure all connecting rod bearing caps are
marked so they can be installed in their original
positions.
4. Turn the crankshaft until the connecting rod
(6200) being removed is down.
5. Remove the connecting rod nuts and connecting
rod bearing cap.
6. Push the connecting rod and piston out through
the top of the cylinder with the handle end of a
hammer or a suitable piston hammer. Avoid
damage to the crankshaft journal and
cylinder wall when removing the piston and
connecting rod.
7. Remove the connecting rod bearings (6211) from
A10397-C the connecting rod and connecting rod bearing
cap.
10. Clean the oil pump screen cover and tube (6622).
Prime the oil pump by filling the inlet opening with 8. Install the connecting rod bearing cap on the
oil and rotate the oil pump intermediate shaft connecting rod from which it was removed.
(6A618) until oil emerges from the outlet opening. Installation
11. Install the oil pan and oil pump. Refer to Oil Pan 1. If new partial piston ring sets (6148) are to be
and / or Oil Pump Screen Cover and Tube in this installed, remove the cylinder wall glaze. Refer to
section. Section 03-00. Clean cylinder bores with soap
12. Fill the crankcase. Start the engine (6007) and and water after honing or deglazing. Dry and oil
check for oil pressure. Operate the engine at fast immediately after cleaning.
idle and check for oil leaks. 2. Oil the partial piston ring sets, pistons and
cylinder walls with recommended quality engine
oil. Be sure to install pistons into cylinders
from which they were removed or to which
Pistons and Connecting Rods they were fitted. Connecting rod and
connecting rod bearing caps are numbered
Removal from 1 to 4 in the right bank, and 5 to 8 in the
1. Drain the crankcase. Drain the cooling system. left bank, beginning at the front of engine
Refer to Section 03-03. Remove the lower intake (6007). Numbers on the connecting rod and
manifold (9424), cylinder heads (6049), oil pan connecting rod bearing cap must be on the
(6675) and oil pump (6600). Refer to Intake same side when installed in the cylinder
Manifold, Lower, Cylinder Heads, and Oil Pan bore. If a connecting rod is ever transposed
and / or Oil Pump Screen Cover and Tube in this from one cylinder block (6010) or cylinder to
section. another, new connecting rod bearings
should be fitted and the connecting rod
should be numbered to correspond with the
new cylinder'number.
ALL RIGHTS RESERVED
03-01C-39 Engine, 7.5L MFI v-a 03-01C-39
3. Make sure piston ring gaps (oil ring spacer A, oil 7. After the connecting rod bearings have been
ring segments B, and compression rings C) are fitted, apply a light coat of recommended quality
properly spaced around circumference of piston. engine oil to the journals and connecting rod
bearings.
8. Install the connecting rod bearing cap. Make sure
connecting rod bolt heads are properly seated in
the connecting rod. lighten the nuts to 61-68 N·m
(45-50 Ib-ft).
9. 'After the piston and connecting rod assemblies
have been installed, check the side clearance
between the connecting rods on each crankshaft
journal. Refer to Section 03-00.
10. Measure piston deck height as follows:
a. Set up Oiallndicator with Bracketry
TOOL-4201-C or equivalent as shown.
C
PISTON
6108
A2811-C
4. Turn the crankshaft until the connecting rod
journal reaches the bottom of its stroke.
c;:::.
5. Install Piston Ring Compressor 081L-6002-C or _ _ _ _ c::::> ----..;~~-=----:~
equivalent on piston and push in with hammer
handle or a suitable piston hammer until it is
slightly below top of cylinder. Be sure to guide
------IT
DIAL INDICATOR WITH BRACKETRY TOOL-4201.C
,-
connecting rods while tapping them into position A21UI-A
to avoid damaging crankshaft journals. Install
piston with indentation notch in piston head b. Turn the crankshaft in normal direction of
toward front of engine. Push the piston down rotation until the piston is flush with the deck
into the cylinder until the connecting rod face of the cylinder block. Use a straightedge
bearings seat on the crankshaft journal. laid on the cylinder block deck across the
piston bore to determine the piston resting at
the flush location.
c. Set the dial indicator to zero at this point. The
probe of the dial should have some pressure
against it before setting the indicator at zero.
d. Now, continue rotating the crankshaft slowly
until the piston is at TOC. Read the dial
indicator.
If the dial recorded a reading, this denotes that the
piston is protruding above the cylinder block by the
measurement noted on the dial. Compare the reading
with the specification for the model year of the vehicle.
If the dial did not record any protrusion in Step b, then
the piston is either flush with the cylinder block deck,
or, is below the deck face. To determine the amount of
piston recession below the cylinder block deck,
perform the following:
e. Remove dial indicator,from engine.
f. Rotate the crankshaft until the piston reaches
6. Check clearance of each connecting rod bearing TOC.
using Plastigage @ or equivalent. Refer to Section
03-00. g. Use a known, good straightedge and lay it on
the cylinder block deck across the cylinder
bore.
ALL RIGHTS RESERVED
03-01C-40 Engine, 7.5L MFI v-a 03-01C-40
h. Measure the gap (if any) between the top of 4. Clean the crankshaft journal. When replacing
the piston crown and the straightedge using a standard connecting rod bearings with new
feeler gauge. connecting rod bearings, it is good practice to fit
This measurement determines the amount of piston the connecting rod bearing to minimum specified
recession below the deck face. Compare this with the clearance. Refer to Specifications in this section.
specification for the model year of the vehicle. Installation
11. Disassemble, clean and inspect oil pump. Refer to Refer to Section 03-00 for cleaning and inspection
Section 03-00. Reas~emble or replace oil pump procedures.
as required. Clean the oil pump screen cover and
tube (6622), oil pan, and the block gasket 1. Fit connecting rod bearings using Plastigage® or
surfaces. equivalent. Refer to Section 03-00.
12. Prime the oil pump by filling the inlet port with 2. Install the connecting rod bearing in the
engine oil and rotating the oil pump intermediate connecting rod and connecting rod bearing cap
shaft (6A618) to distribute oil within the housing. with tangs in the slots provided.
Install the oil pump and the oil pan. Refer to Oil 3. Pull the connecting rod assembly down firmly on
Pan and / or Oil Pump Screen Cover and Tube in the crankshaft journal (guide connecting rod to
this section. prevent crankshaft journal damage).
13. Install the cylinder heads. Refer to Cylinder 4. Apply a light coat of specified engine oil to the
Heads in this section. journal and connecting rod bearing. Install the
14. Install the lower intake manifold. Refer to Intake connecting rod bearing cap. Make sure the
Manifold, Lower in this section. connecting rod bolt heads are properly seated in
the connecting rod. Tighten the nuts to 61-68 N·m
15. Fill and bleed the cooling system. Refer to (45-50 Ib-ft).
Section 03-03. Fill the crankcase to the correct
level with the specified engine oil. 5. Repeat the procedure for the remaining
connecting rods that require new connecting rod
16. Start the engine and adjust the ignition timing to bearings.
specifications listed on the engine decal.
6. Install oil pan, oil pump and related parts. Refer to
17. Operate the engine at fast idle and check for oil Oil Pan and / or Oil Pump Screen Cover and Tube
and coolant leaks after the engine temperature in this section.
has stabilized.
18. Install the engine air cleaner (ACL)(9600) and air
cleaner outlet tube (98659).
Flywheel
Removal
Connecting Rod Bearings 1. Remove the transmission (7003) from vehicle.
Refer to Section 07-01 A, 07-018, 07-03A or
Removal 07-038. Remove the flywheel mounting bolts and
1. Drain the crankcase. Remove the oil level remove flywheel (6375) from the crankshaft
dipstick (6750). Remove the oil pan (6675), oil (6303).
pump (6600) and related parts. Refer to Oil Pan 2. Refer to Section 03-00 for inspection.
and / or Oil Pump Screen Cover and Tube in this
section. Installation
2. Turn the crankshaft (6303) until connecting rod 1. Install flywheel on crankshaft. Install the mounting
(6200) to which new bearings are to be fitted is bolts. lighten to 103-115 N·m (75-85Ib-ft).
down. Remove the connecting rod bearing cap. 2. Check flywheel runout and flywheel ring gear
Remove the connecting rod bearings (6211) from runout using Dial Indicator with 8racketry
connecting rod and connecting rod bearing cap. 014-00282 or equivalent. Refer to Specifications
3. Make sure connecting rod bearings and bearing in this section. If readings are not within
bore in connecting rod and connecting rod specification, replace flywheel.
bearing cap are clean. Foreign material under
connecting rod bearings will distort connecting
rod bearing and cause a failure.
ALL RIGHTS RESERVED
03-01C-41 Engine, 7.5L MFI v-a 03-01C-41
3. Install transmission assembly into vehicle. Refer Installation

to Section 07-01A, 07-018, 07-03A or 07-038. 1. Carefully clean the seal groove in the rear
crankshaft main bearing cap and cylinder block
with a brush and solvent such as lacquer thinner,
Extra Strength Spot and Stain Remover,
87A-19521-AA or equivalent meeting Ford
specification ESR-M58 197-A. Also, clean the
area where sealer is later to be applied. Dry the
area thoroughly, so that no solvent touches the
crankshaft rear oil seal.
2. Dip the split lip-type seal halves in clean engine
oil.
3. CAUTION: Be sure no rubber has been
shaved from the outside diameter of the
crankshaft rear oil seal by the bottom edge
of the groove. Do not allow oil to get on the
sealer area.
Carefully install the upper half of the crankshaft
rear oil seal ( cylinder block) into its groove with
undercut side of crankshaft rear oil seal toward
the FRONT of the engine (6007)(with the tab side
of the crankshaft rear oil seal directed toward the
rear face of the cylinder block), by rotating it on
A10078·B
the seal journal of the crankshaft until
approximately 9.525mm (3/8 inch) protrudes
below the parting surface.
Mainshaft Bearing Roller

Refer to Section 08-01 for Removal and Installation
procedures.
Crankshaft Rear Oil Seal

Removal
1. Remove the oil pan (6675). Refer to Oil Pan
and / or Oil Pump Screen Cover and Tube in this
section.
2. Loosen all the crankshaft main bearing cap bolts,
thereby lowering the crankshaft (6303) slightly
but not to exceed 0.7938mm (1/32 inch).
3. CAUTION: Use care to prevent scratching or A2639-H
damaging the crankshaft sealing surfaces.
Part
Remove the rear crankshaft main bearing cap,
and remove the crankshaft rear oil seal (6701) Item Number Description
from the rear cran~haft main bearing cap and 1 6010 Cylinder Block
cylinder block (6010). On the cylinder block half 2 6701 Crankshaft Rear Oil Seal
of the crankshaft rear oil seal use a seal removal 3 - Tab (Part of 6701)
tool, or install a small metal screw in one end of 4 - Crankshaft Rear Main
the crankshaft rear oil seal, and pull on the screw Bearing Cap (Part of 6010)
to remove the crankshaft rear oil seal. 5 - 9.53mm (3/8 Inch)
4. Tighten the remaining crankshaft main bearing

cap bolts to specifications. Refer to
Specifications in this section.
ALL RIGHTS RESERVED
03-01C-42 Engine, 7.5L MFI v-a 03-01C-42
5. Install the lower half of the crankshaft rear oil seal

in the rear crankshaft main bearing cap with Part
undercut side of crankshaft rear oil seal toward Item Number Description
the FRONT of the engine with the tab side of the 3 6701 Crankshaft Rear Oil Seal
crankshaft rear oil seal directed toward the rear 4 - Rear Face of 6010
face of the cylinder block). Allow the crankshaft 5 - Wire Seal Retainer
rear oil seal to protrude approximately 9.525mm (Part of 6701)
(3/8 inch) above the parting surface to mate with
the upper half of the crankshaft rear oil seal when Install the rear crankshaft main bearing cap. lighten
the rear crankshaft main bearing cap is installed. the bolts to specifications listed at the end of this
6. NOTE: This sealer sets-up in 15 minutes. section.
Apply a continuous even 1.588mm (1 / 16 inch) 7. Install the oil pump (6600) and oil pan. Refer to Oil
diameter bead of Gasket Maker E2AZ-19562-B Pan and / or Oil Pump Screen Cover and Tube in
or equivalent meeting Ford specification this section. Fill the crankcase with the proper
WSK-M2G348-A5 to the crankshaft rear oil seal amount and type of oil.
area of the cylinder block starting from the 8. Operate the engine and check for oil leaks.
forward face of the oil return groove and
overlaying end of wire seal retainer. Do not allow
sealer to contact inside diameter of the
crankshaft rear oil seal. Camshaft Rear Bearing Cover
Removal
1. Remove the transmission (7003) from the
vehicle. Refer to Section 07-01A, 07-01B,
.,
FRONT OF ENGINE 2.
3.
07-03A or 07-03B.
Remove flywheel (6375) and engine rear plate
(7007).
Replace the camshaft rear bearing cover (6266).
Refer to Engine Block Plug service procedure in
Section 03-00.
Installation
1. Install the engine rear plate and flywheel.
2. Install the transmission. Refer to Section 07-01A,
07-01B, 07-03A or 07-03B.
VIEW A
Oil Bypass Filter
Removal
1. Place a drip pan under the oil bypass filter
(6714). Unscrew the oil bypass filter from the
engine oil cooler (6B856) using an oil filter
wrench. Clean the oil filter mounting insert (6890)
or engine oil cooler recess. Clean the oil bypass
filter gasket surface. Make sure oil bypass filter
gasket is not stuck on oil filter mounting insert or
engine oil cooler.
Installation
1. Coat the oil bypass filter gasket on a new oil
bypass filter with specified engine oil. Place the
A23629·A new oil bypass filter on the oil filter mounting
insert or engine oil cooler. Hand-tighten the oil
Part bypass filter until the oil bypass filter gasket
contacts the sealing surface, then tighten another
one-half turn.
2 E2AZ-19562-B Gasket Maker (2 Places)
(Continued)

ALL RIGHTS RESERVED
03-01C-43 Engine, 7.5L MFI v-a 03-01C-43
2. Add one quart of oil. Operate the engine (6007) 2. Raise the vehicle. Refer to Section 00-02.
at fast idle and check for oil leaks. If oil leaks are 3. Remove the oil bypass filter (6714).
evident, perform the necessary repairs to correct
the leakage. Check the oil level and fill the 4. Disconnect the lower radiator hose (8286) from
crankcase to the correct level. the engine oil cooler (68856).
5. Loosen the hose clamp securing the engine oil
cooler hose to the water pump (8501).
.,
FRONT OF ENGINE
6.
7.
Remove the oil filter adapter mounting bolt
(6894).
Disconnect the engine oil cooler hose at the
water pump and remove the engine oil cooler.
8. Disconnect the engine oil cooler hose from the
engine oil cooler.
OIL BYPASS 9. If necessary, remove the oil filter mounting insert
FILTER (6890).
6714
10. Clean the engine oil cooler with a commercially
available, environmentally safe solvent and dry
with compressed air.
11. Inspect the engine oil cooler for sludge deposits,
house cracks, bent hose connections or other
ENGINE OIL visible damage. Replace the engine oil cooler if
COOLER
6B856 any damage is found.
A15118-C
Engine Oil Cooler

Removal
1. Drain the engine cooling system. Refer to Section
03-03.
ALL RIGHTS RESERVED
03-01C-44 Engine, 7.5L MFI v-a 03-01C-44
Engine 011 Cooler Installation
•
FRONT OF ENGINE
•
FRONT OF ENGINE
A13823-D
Part Part
1 6714 Oil Bypass Filter 6 6N753 Engine Oil Cooler Hose
2 6B856 Engine Oil Cooler 7 - Engine Oil Cooler Adapter
3 8501 Water Pump (Part of 6B856)
4 - Water Pump Inlet 8 6894 Oil Filter Adapter Mounting
(Part of 8501) Bolt
5 39100 Clamp 9 6890 Oil Filter Mounting Insert
(Continued)
Installation 5. Install the oil filter adapter mounting bolt and

1. If removed, install the oil filter mounting insert and tighten to 54-88 N·m (40-65Ib-ft).
tighten to 61-203 N·m (45-150 Ib-ft). 6. Tighten both hose clamps securing the engine oil
2. Connect the engine oil cooler hose to the engine cooler hose to 1.6-2.8 N·m (15-25Ib-in).
oil cooler and slide both hose clamps over the 7. Connect the lower radiator hose to the engine oil
engine oil cooler hose. cooler and tighten the hose clamp to 3-4 N·m
3. Push the engine oil cooler hose onto the water (27-35 Ib-in).
pump inlet until bottomed against inlet ridge. Align 8. Coat the oil bypass filter gasket on a new oil
arrow on engine oil cooler hose with notch on inlet bypass filter with specified engine oil. Place the
ridge. new oil bypass filter on the engine oil cooler and
4. Install the engine oil cooler by piloting the adapter hand-tighten until the oil bypass filter gasket
portion onto the oil filter mounting insert. contacts the sealing surface, then tighten an
additional one-half turn.

ALL RIGHTS RESERVED
03-0 1C-45 Engine, 7.5L MFI v-a 03-01C-45
9. Lower the vehicle. Refer to Section 00-02.

10. Fill the crankcase with the proper grade and
quantity of engine oil.
11. Fill and bleed the engine cooling system. Refer to
Section 03-03.
12. Operate the engine at fast idle and check for
engine oil and coolant leaks. If leaks are evident,
perform the necessary repairs to correct the IIIP-
leakage. FRONT OF ENGINE
Oil Level Indicator Tube

1. Remove the oil level dipstick (6750).
2. Clean the area where the oil level indicator tube
(6754) connects to the oil pan (6675).
3. Remove the nut securing the oil level indicator
tube support to the exhaust manifold stud.
4. Remove the clip retaining the oil level indicator
tube to the oil pan.
5. Remove the oil level indicator tube.
6. Cover the opening in the oil pan to prevent any
contaminants from entering the oil pan.
7. For installation, follow the removal procedures in
reverse order. Tighten the retaining nut to 13-24
N·m (10-18Ib-ft).
VIEW A
A2363D-A
Part
1 6750 Oil Level Dipstick
2 391335-S101 3/8-16 x 3.77 Hex Shoulder
Flange Stud
3 6675 Oil Pan
4 N808064-S 100 Clip
5 - Oil Pan Adapter
(Part of 6675)
6 6754 Oil Level Indicator Tube
7 382802-S2 3/8-16 Nut
( 10-18 Lb-Ft)
Sensors
Oil Pressure Sender (Switch)
1. Disconnect the wire at the oil pressure sensor
(9278).

ALL RIGHTS RESERVED
03-0 1C-46 Engine, 7.5L MFI v-a 03-01C-46
2. Prepare the new oil pressure sensor for 6. Remove the engine air cleaner and air cleaner
installation by applying Pipe Sealant with Teflon@ outlet tube, including the crankcase ventilation
D8AZ-19554-A or equivalent meeting Ford hose (6853). Disconnect the fuel vapor return
specification WSK-M2G350-A2 or a small valve from the wiring harness connector and
amount of electrically conductive sealer to the remove the fuel vapor return hose and valve
threads. assembly from the positive crankcase ventilation
3. Remove the oil pressure sensor from its mounting valve (PCV valve)(6A666).
and immediately install the new oil pressure 7. Disconnect the lower radiator hose (8286) and
sensor. Tighten to 11-24 N·m (8-18Ib-ft). upper radiator hose (8260) at the radiator
4. Connect wire to oil pressure sensor. (8005). If equipped with an automatic
transmission (7003), disconnect the transmission
5. Start the engine (6007) and check the operation oil cooler lines.
of the oil pressure sensor.
8. If so equipped, discharge the air conditioning
system and remove the A / C condenser core
Oil Pressure (Sender Switch) 7.5L Gas Engine (19712). Refer to the Body, Chassis Manual,
Section 12-03A. Disconnect air conditioning lines
OIL PRESSURE at the A / C compressor (19703). Disconnect
SENDER-9278 compressor clutch electrical lead.
~ 9. Remove the fan shroud (8146) and position it
FRONT OF over the fan blade (8600). Remove the radiator.
ENGINE
Refer to Section 03-03. Remove the fan shroud,
fan clutch (8A616), drive belts (8620) and water
pump pulley (8509).
\"- TRANSMISSION
7003
K12784-D
Engine

Engine Lifting Brackets T70P-6000
Removal
1. Drain the crankcase. Drain the cooling system.
Refer to Section 03-03. Remove hood. Refer to Part
Section 01-02. Item Number Description
2. Disconnect the battery ground cable (14301) 1 8501 Water Pump
from the battery. 2 8509 Water Pump Pulley
3. Disconnect the secondary air injection manifold 3 8600 Fan Blade
tube (98449) at the right-hand side of the engine 4 8A616 Fan Clutch
air cleaner (ACL)(9600). Perform all pre-service 5 380288·52 Screw and Washer
procedures. Refer to Section 03-04C. Assembly
4. Disconnect the air cleaner outlet tube (98659) at 6 57632-52 Screw and Washer
the throttle body (9E926) and upper intake Assembly
manifold (9424). The engine air cleaner and air A - Tighten to 16-24 N·m
cleaner outlet tubes can now be removed, after (12-18 Lb-Ft)
disconnecting the engine air cleaner hot air tube
(9652) at the engine air cleaner. 10. Remove the generator bolts and allow the
generator (GEN)(10300) to swing down and out
5. Remove the secondary air injection silencer inlet of the way.
hose (9J435) connected to the engine air cleaner
hot air tube and remove the engine air cleaner hot
air tube.

ALL RIGHTS RESERVED
03-01C-47 Engine, 7.5L MFI v-a 03-01C-47
11. Disconnect throttle and transmission linkage at Engine Supports, F-250, F-350 and F-Super Duty
throttle body and remove accelerator cable
bracket (9723) from upper intake manifold.
Remove the speed control hardware if so
equipped.
12. Disconnect the wiring harness from the oil
pressure sensor. Disconnect evaporative
emission hoses at the evaporative emissions
canister (EVAP canister)(9D653).
13. Disconnect the fuel lines at quick disconnect
couplings and vacuum lines to the intake manifold.
14. Disconnect EGR valve to exhaust manifold tube
(9D477) at left exhaust manifold (9431) and
upper intake manifold. Plug manifold opening.
15. Disconnect power brake booster vacuum hose, if
so equipped.
16. Disconnect the heater hoses from the water
pump (8501) and intake manifold.
17. Disconnect secondary air injection silencer inlet
hose at diverter valve.
18. Remove the flywheel housing-to-engine upper
bolts.
19. Disconnect the ground strap from the cylinder
block (6010).
20. Remove the oil level dipstick (6750) and oil level
indicator tube (6754). Refer to the procedure in
this section.
21. Raise the front of the vehicle. Disconnect the
starter cable from the starter motor (11002).
Remove the starter motor. Refer to Section
03-06A.
22. Disconnect the muffler inlet pipes from the A23631·A
left-hand exhaust manifold (9430) and right-hand
exhaust manifold. Disconnect the front engine Part
support insulators (6038) from the right-hand Item Number Description
front engine support bracket (6028) and left-hand
1 N803203-S 100 Screw and Washer,
front engine support bracket (6029) on the frame M 12-1.75 x 35
underbody.
2 6038 Front Engine Support
23. Raise the engine slightly and carefully pull it from Insulator
the transmission. Carefully lift the engine out of 3 6028 Front Engine Support
the engine compartment so that the engine rear Bracket
plate (7007) is not bent or other components 4 N807479-S301 Nut and Washer, M 12-1.75
damaged. Install the engine on a work stand. 5 387811-S100 Screw and Washer,
7/16-14 x 1
6 6030 Front Engine Support
Mounting Bracket
7 6C038 Engine Mount Heat Shield
(Left-Hand Only)
(80-109 Lb-Ft)
B - Tighten to 87.5-118.5 N·m
(64-87 Lb-Ft)
(60-80 Lb-Ft)
ALL RIGHTS RESERVED
03-0 1C-48 Engine, 7.5L MFI V-8 03-01C-48
Engine Support, F-Super Duty Motorhome Chassis
FRONT OF VEHICLE
~
~© A12973-C
Part Part
1 N800937-S109 Nut 8 N802320-S2 Nut-
2 N802114-S12 Bolt 9 N802114-S Bolt
3 6038 Front Engine Support 10 6028 Front Engine Support
Insulator Bracket (Right-Hand)
4 6049 Front Engine Support A - Tighten to 58- 77 N·m
Mounting Bracket (43-57 Lb-Ft)
5 387811-S Bolt B - Tighten to 81-109 N·m
6 6C038 Engine Mount Heat Shield (60-80 Lb-Ft)
(Left-Hand Only) C - Tighten to 96-127 N·m
7 6029 Front Engine Support (71-94 Lb-Ft)
Bracket (Left-Hand)
(Continued)
24. Using a Rotunda Low Lift Transmission Jack 26. Lower the vehicle, and then support the
077-00008 or equivalent, support transmission. transmission. Install Engine Lifting Brackets
25. On a vehicle with automatic transmission, remove T70P-6000 onto the right-hand front engine lifting
the transmission housing cover (7986). Remove eye (17A084) and left-hand rear engine lifting
the torque converter-to-flywheel attaching bolts. eye. Attach the engine lifting sling.
Remove transmission-to-engine bolts. Installation
On vehicles with manual transmission, remove the 1. Attach Engine Lifting Brackets T70P-6000 and
engine rear plate from the flywheel housing. sling. Remove the engine from the work stand.
Remove the remaining flywheel housing-to-engine
bolts.

ALL RIGHTS RESERVED
03-01C-49 Engine, 7.5L MFI v-a 03-01C-49
2. Lower the engine carefully into the engine

~
compartment. Make sure the flywheel housing to and reconnected, some abnormal drive
block dowels (6397) in the cylinder block are symptoms may occur while the powertrain
through the engine rear plate, then engage control module (PCM)( 12A650) relearns its
flywheel housing to block dowels with holes in the adaptive strategy. The vehicle may need to be
flywheel housing. driven 10 miles or more to relearn the strategy.
On a vehicle with manual transmission, start the Position the generator (GEN)( 10346) and install
input shaft (7017) into the clutch disc (7550). It the generator bolts. Connect the battery ground
may be necessary to adjust the position of the cable. Adjust the drive belt tension to
transmission in relation to the engine if the input specification. Refer to Section 03-05.
shaft will not enter the clutch disc. If the engine 16. If so equipped, connect the air conditioning lines
hangs up after the input shaft enters, turn to the A I C compressor.
the crankshaft (6303) slowly (transmission in
gear) until the shaft splines mesh with the 17. Install the radiator. Refer to Section 03-03.
clutch disc splines. Connect the upper radiator hose and lower
radiator hose. Connect the transmission oil cooler
3. Install the flywheel housing upper bolts. lines, if so equipped. Install the fan shroud.
4. Install the front engine support insulator-to-front 18. If so equipped, install the A/C condenser core to
engine support bracket nuts and washers. the radiator. Refer to the Body, Chassis Manual,
Tighten to 87.5-118.5 N·m (64-87 Ib-ft) for F-250, Section 12-03A.
F-350 and F-Super Duty, 96-127 N·m (71-94
Ib-ft) for F-Super Duty Motorhome Chassis. 19. Perform all·post-service procedures. Refer to
Disconnect the engine lifting sling. Section 03-04C.
5. Install the remaining flywheel housing-to-engine 20. Connect the heater hoses to the water pump and
bolts. intake manifold. Fill and bleed the cooling system.
Refer to Section 03-03. Fill the crankcase with
6. On a vehicle with automatic transmission, install the proper grade and quantity of oil. Connect the
the converter-to-flywheel attaching bolts. Install booster vacuum hose, if so equipped.
the transmission housing cover or the engine rear
plate on manual transmissions. 21. Operate the engine at fast idle and check all
gaskets and hose connections for leaks.
7. Remove the Rotunda Low Lift Transmission Jack
077-00008 or equivalent from the transmission 22. Install the engine air cleaner and air cleaner outlet
and lower the vehicle. Remove the Engine Lifting tube assembly. Connect the crankcase ventilation
Brackets T70P-6000. hose to the engine air cleaner.
8. Raise the front of the vehicle. Connect the muffler 23. Install the fuel vapor return hose and valve
inlet pipes to the left exhaust manifold and right assembly to the positive crankcase ventilation
exhaust manifold. Tighten the nuts to 34-49 N·m valve and connect the fuel vapor return valve to
(25-36 Ib-ft). the wiring harness connector.
9. Position and install the starter motor and the 24. Install the engine air cleaner hot air tube and
starter cable. Refer to Section 03-06A. connect the secondary air injection silencer inlet
hose.
10. If so equipped, connect the air conditioning
compressor magnetic clutch lead wire. 25. Install the air cleaner outlet tube to the throttle
body and upper intake manifold.
11. Connect the wiring harness to the oil pressure
sensor. 26. Connect the secondary air injection manifold tube
to the right-hand side of the engine air cleaner.
12. Connect the accelerator cable bracket to the
upper intake manifold. Connect the transmission 27. Evacuate and charge the air conditioning system,
and throttle linkage to the throttle body and if so equipped. Refer to the Body, Chassis
speed control linkage, if so equipped. Manual, Section 12-00.
13. Connect the fuel lines. Reconnect evaporative 28. Install hood. Refer to the Body, Chassis Manual,
emission hoses at the evaporative emissions Section 01-02.
canister.
14. Install the water pump pulley, drive belts, fan
clutch and fan blade. Position the fan shroud over
the fan blade. Camshaft Bearings
Camshaft bearings (6261) are available prefinished to
size for standard and undersize journal diameters.

Camshaft Bearing Set T65L-6250-A

ALL RIGHTS RESERVED
03-01C-50 Engine, 7.5L MFI v-a 03-01C-50
Removal 5. Repeat the procedure for each camshaft bearing.

1. With engine (6007) removed and placed in a work To remove the front camshaft bearing, install
stand, remove the camshaft (6250) and flywheel puller screw from rear of cylinder block (6010).
(6375). Refer to Camshaft and Flywheel in this Installation
section. Push pistons to top of cylinders.
1. CAUTION: Failure to use correct expanding
2. Remove the camshaft rear bearing cover (6266). collet can cause severe bearing damage.
Refer to Engine Block Plug service procedure in Align oil holes in camshaft bearings with oil
Section 03-00. holes in cylinder block before pressing them
3. Using Camshaft Bearing Set T65L-6250-A, into block. Be sure front camshaft bearing is
select the proper size expanding collet and installed 0.051-0.762mm (0.002-0.003
backup nut and assemble onto expanding inches) below front face of cylinder block.
mandrel. With the expanding collet collapsed, Position new camshaft bearings at bearing bores,
install the collet in the camshaft bearing. lighten and press in place with the tool. Be sure to center
backup nut on expanding mandrel until collet fits the pulling plate and puller screw to avoid bearing
camshaft bearing. damage.
4. Assemble the puller screw and extension, if 2. Install a new camshaft rear bearing cover. Refer
necessary, as shown and install on expanding to Engine Block Plug service procedure in Section
mandrel. Wrap a cloth around threads of the 03-00.
puller screw to protect the front camshaft bearing
or journal. TIghten pulling nut against the thrust 3. Install camshaft and flywheel. Refer to Camshaft
bearing and pulling plate to remove camshaft and Flywheel in this section.
bearing. Hold a wrench on the end of puller screw 4. Install engine into vehicle. Refer to Engine
to prevent it from turning. installation in this section.
Camshaft Bearings, Removal/Installation
Part Part
1 - Pulling Screw 6 6262 Bearing, Camshaft
(Part of T65L-6250-A) (Part Number Given Is for
2 - Pulling Plate Reference Only)
(Part of T65L-6250-A) 7 - Puller Screw Extension
3 - Expanding Mandrel (Part of T65L-6250-A)
(Part of T65L-6250-A) 8 - Front Spacer
4 - Expanding Collet (Part of T65L-6250-A)
(Part of T65L-6250-A) NOTE: All Items Except No.6
(Bearing) Are Included in
5 - Backup Nut
Camshaft Bearing Set
(Part of T65L-6250-A)
T65L-6250-A.
(Continued)
ALL RIGHTS RESERVED
03-01C-51 Engine, 7.5L MFI v-a 03-01C-51
A171M3-B
5. Slide crankshaft damper spacer off crankshaft.

6. Remove the engine front cover (6019) and water
pump as an assembly. Check the timing chain
deflection. Refer to Section 03-00. Remove the
timing chain, camshaft sprocket (6256) and
crankshaft sprocket (6306). Refer to Timing
Crankshaft Chain and Sprockets in this section.
To perform the following operation, it is necessary to 7. Invert the engine on a work stand. Remove the
remove the engine (6007) and install it on a work flywheel (6375) and the engine rear plate (7007).
stand. Remove the oil pan (6675) and oil pan gasket
(6710). Remove the oil pump (6600).
SPECIAL SERVICE TOOL(S) REQUIRED 8. Make sure all bearing caps (crankshaft main and
connecting rod), are marked for installation into
Description Tool Number their original locations.
Spark Plug Wire Remover T74P-6666-A Turn the crankshaft until the connecting rod
Crankshaft Damper Remover T58P-6316-D (6200) from which connecting rod bearing cap is
being removed is up, then remove the connecting
Removal rod bearing cap. Push the connecting rod and
1. Disconnect the distributor to spark plug wires piston (6108) assembly down into the cylinder.
( 12286) from the spark plugs (12405) using Repeat this procedure until all connecting rod
Spark Plug Wire Remover T74P-6666-A. Remove bearing caps are removed.
the spark plugs to allow easy rotation of 9. Remove the crankshaft main bearing caps.
crankshaft (6303).
10. Carefully lift the crankshaft out of the cylinder
2. Remove the oil bypass filter (6714). Slide water block (6010) so thrust bearing surfaces are not
pump bypass clamp toward the water pump damaged. Handle the crankshaft with care to
(8501). avoid possible fracture or damage to finished
3. Remove the crankshaft pulley (6312) from the surfaces.
crankshaft vibration damper (6316). Refer to Section 03-00, for cleaning and
4. Remove the bolt and washer from the end of the inspection procedures. Clean the crankshaft
crankshaft. Install Crankshaft Damper Remover vibration damper.
T58P-6316-D or Rotunda Gear and Pulley Puller To refinish journals and dress minor imperfections
014-00293 or equivalent on the crankshaft refer to Section 03-00.
vibration damper and remove crankshaft
vibration damper. Remove Woodruff key.

ALL RIGHTS RESERVED
03-01C-52 Engine, 7.5L MFI v-a 03-01C-52
Crankshaft Assembly
A10399·F
Part. Part
1 42998-S8 Bolt 11 6333 Crankshaft Main Bearing
2 6312 Crankshaft Pulley 12 6337 Crankshaft Thrust Main
3 376706-S Bolt Bearing
4 6378 Washer 13 6701 Crankshaft Rear Oil Seal
(Upper and Lower Halves)
5 6316 Crankshaft Vibration
Damper 14 6375 Flywheel
6 6359 Crankshaft Damper Hub 15 - Crankshaft Main Bearing
Caps (Part of 6010)
7 6306 Crankshaft Sprocket
8 74151-S Key
(40-53 Lb-Ft)
9 388907-S Key
10 6303 Crankshaft
(70-90 Lb-Ft)
(Continued)
Installation 4. NOTE: If the original crankshaft main bearings

1. Remove the crankshaft rear oil seal (6701) from and crankshaft thrust main bearings (6337) are
cylinder block and rear crankshaft main bearing to be reused, all crankshaft main bearings and
cap. crankshaft thrust main bearings should be
marked for installation into their original locations.
2. Remove the crankshaft main bearings (6333)
from the cylinder block and crankshaft main If the crankshaft main bearing journals have been
bearing caps. refinished to a definite undersize, install the
correct undersize crankshaft main bearing and
3. Remove the connecting rod bearings (6211) from crankshaft thrust main bearing. Make sure
the connecting rods and connecting rod bearing crankshaft main bearings and crankshaft thrust
caps. main bearings and bearing bores are clean.
Foreign material under crankshaft main bearings
and crankshaft thrust main bearings will distort
the crankshaft main bearings and crankshaft
thrust main bearings and cause failure.

ALL RIGHTS RESERVED
03-01C-53 Engine, 7.5L MFI v-a 03-01C-53
5. CAUTION: The oil holes in the upper half of Tightening Crankshaft Thrust Main Bearing Cap
~ the crankshaft main bearings and crankshaft
thrust main bearings must be aligned with
the oil holes in the cylinder block.
Place the upper half of the crankshaft main
bearings and crankshaft thrust main bearings in
the bores with tang in slot.
6. Install lower half of the crankshaft main bearings
and crankshaft thrust main bearings in crankshaft
main bearing caps.
7. Clean the rear journal oil seal groove and mating
surfaces of the cylinder block and rear
crankshaft main bearing cap.
8. Install a new crankshaft rear oil seal in the
cylinder block and rear crankshaft main bearing
cap. Refer to Crankshaft Rear Oil Seal in this
section.
9. Carefully lower the crankshaft into place. Be
careful not to damage crankshaft main
bearing and crankshaft thrust main bearing
surfaces.
10. Check the clearance of each crankshaft main
bearing and crankshaft thrust main bearing with
Plastigage @ or equivalent. Refer to Section
03-00.
11. After crankshaft main bearings and crankshaft A10397-C
thrust main bearings have been fitted, apply light
coat of specified engine oil to journals and 15. Retain forward pressure on the crankshaft.
crankshaft main bearings and crankshaft thrust Tighten crankshaft main bearing cap bolts to
main bearings. Install all crankshaft main bearing 129-142 N·m (95-105 Ib-ft).
caps except thrust bearing cap (No.3). Make
sure crankshaft main bearing caps are 16. Force the crankshaft toward the rear of engine.
installed in original locations. Tighten the 17. Check the crankshaft end play. Refer to Section
bearing cap bolts to 129-142 N·m (95-105Ib-ft). 03-00.
12. Install the crankshaft thrust main bearing cap with 18. Install new connecting rod bearings in the
bolts finger-tight. connecting rods and connecting rod bearing
13. Pry the crankshaft forward against thrust surface caps. Check clearance of each connecting rod
of upper half of crankshaft thrust main bearing. bearing with Plastigage @ or equivalent. Refer to
Section 03-00. Also, refer to Specifications in this
14. Hold crankshaft forward and pry thrust bearing section. .
cap to rear. This aligns the rear thrust surfaces of
both halves of crankshaft thrust main bearing. 19. After the connecting rod bearings have been
fitted, apply light coat of specified engine oil to
journals and connecting rod bearings.
20. Turn the crankshaft throw to bottom of its stroke.
Pull the piston all the way up until connecting rod
bearing seats on the crankshaft journal. Cover
connecting rod bolt ends with section of rubber
hose to prevent crankshaft journal damage during
installation.
21. Install the connecting rod bearing cap. Make sure
connecting rod bolt heads are properly seated in
connecting rod. Tighten nuts to 61-68 N·m (45-50
Ib-ft).
22. After piston and connecting rod assemblies have
been installed, check side clearance between
connecting rods on each crankshaft journal. Refer
to Specifications in this section.

ALL RIGHTS RESERVED
03-01C-54 Engine, 7.5L MFI v-a 03-01C-54
23. Install timing chain, camshaft sprocket and 4. Clean and inspect cylinder head(s) and related
crankshaft sprocket, crankshaft damper spacer, components. Refer to Section 03-00.
engine front cover and crankshaft vibration 5. Refer to Section 03-00 for cylinder head and
damper. Refer to liming Chain and Sprockets in valve repair procedures.
this section.
24. Install the engine rear plate. Position flywheel on Assembly
crankshaft flange. Install and tighten the bolts to Lubricate all valve stems and valve guides with
103-115 N·m (75-85Ib-ft). specified engine oil. Apply Ford Multi-Purpose Grease
25. Clean the oil pan, oil pump and oil pump screen DOAZ-19584-AA or equivalent meeting Ford
cover and tube (6622). Prime the oil pump by specification ESB-M 1C93-A to the valve tips before
filling inlet port with engine oil and rotating oil installation.
pump intermediate shaft (6A618) to distribute oil 1. NOTE: Make sure the proper seal application for
within oil pump housing. Install oil pump and oil intake and exhaust are in place.
pan. Refer to Oil Pan and / or Oil Pump Screen Install each intake valve and exhaust valve in the
Cover and Tube in this section. port from which it was removed or to which it was
26. Install the oil bypass filter. fitted. Install new valve stem seal on each intake
27. Install the spark plugs and connect the distributor valve and exhaust valve.
to spark plug wires. 2. Set valve spring and valve spring retainer over
28. Install the engine in vehicle. Refer to Engine valve stem. Compress valve spring and install
installation in this section. valve spring retainer keys.
3. With dividers, measure assembled height of valve
spring from surface of spring pad on cylinder
DISASSEMBLY AND ASSEMBLY head to underside of valve spring retainer. Check
dividers with accurate scale. If assembled height
exceeds specification, install shim(s) below valve
Engine spring to reduce height to recommended
When installing nuts or bolts that must be tightened, oil dimension. Refer to Specifications in this section.
the threads with light engine oil. Refer to Reducing assembled height below
Specifications in this section for proper torque values. specifications can cause spring breakage
Do not oil threads requiring oil-resistant or and rapid wear of camshaft lobe.
water-resistant sealer.
Subassemblies
Cylinder Head

Valve Spring Compressor T71P-6565-A
Disassembly
1. With cylinder head (6049) removed from engine
(6007), remove rocker arm seat bolts, rocker
arm seats (6A528), and rocker arms (6564).
Remove left exhaust manifold (9431) and right A10.a1-B
exhaust manifold (9430) and spark plugs
(12405). 4. Coat the rocker arm seats and sockets with Ford
2. Clean carbon from combustion chambers before Multi-Purpose Grease DOAZ-19584-AA or
removing intake valves (6507) and exhaust equivalent meeting Ford specification
valves (6505). ESB-M 1C93-A. Make sure the rocker arm seat
bolts are in a serviceable condition before
3. Compress valve springs (6513)using Valve installing them. Install rocker arms, rocker arm
Spring Compressor T71 P-6565-A. Remove valve seats and rocker arm seat bolts. Refer to Rocker
spring retainer key (6518) and release valve Arm in this section.
springs. Remove valve spring retainers (6514),
valve springs, valve stem seals (6571), and 5. Install left exhaust manifold and right exhaust
intake valves and exhaust valves. Discard valve manifold and spark plugs.
stem seals.

ALL RIGHTS RESERVED
03-01C-55 Engine, 7.5L MFI v-a 03-01C-55
Pistons, Piston Pins and Rings Piston and Connecting Rod Removal and
Installation
Piston Pin Remover / Replacer T68P-6135-A
Disassembly
1. Remove the connecting rod bearing (6211) from
the connecting rod (6200) and connecting rod
bearing cap.
2. Mark the pistons (6108) to make sure they are
assembled with same connecting rod and
installed in the same cylinders from which they
were removed.
3. Using an arbor press and Piston Pin
Remover / Replacer T68P-6135-A, press the
piston pin (6135) from the piston and connecting
rod. Remove the partial piston ring set (6148).
Refer to Section 03-00 for cleaning and
inspection procedures. Repair if required.
REMOVAL INSTALLATION
A4871-F
Part
1 - Driver (Part of T68P-6135-A)
2 - Locator
3 - Adapter
4 - Cup (Part of T68P-6135-A)
5 - Pin Pusher
6 6135 Piston Pin
7 - Receiving Tube

ALL RIGHTS RESERVED
03-01C-56 Engine, 7.5L MFI v-a 03-01C-S6
Assembly Valve Tappet, Hydraulic

1. NOTE: Check the fit of a new piston in the Each valve tappet (6500) is a matched assembly. If
cylinder bore before assembling piston and piston parts of one are mixed with those of another, improper
pin to connecting rod. Piston pin bore of valve operation may result. Disassemble and
connecting rod and diameter of piston pin must be assemble each valve tappet separately. Valve tappets
within specifications. should be tested after assembly. Refer to Section
Apply a light coat of specified engine oil to all 03-00. Keep the valve tappets in proper sequence so
parts. Assemble the piston to the connecting rod they can be installed in their original bores.
with the cylinder number side of the connecting Disassembly
rod and indentation notch in piston positioned as
shown. 1. Grasp the lock ring with needlenose pliers to
release it from the groove. It may be necessary to
depress the plunger to fully release lock ring.
2. Remove the push rod cup, metering valve disc,
and plunger assembly.
PISTON 3. Carefully remove the plunger spring, check valve
6108 spring, check valve retainer and check valve from
the plunger.
Refer to Section 03-00 for cleaning and
inspection procedures.
FRONT OF ENGINE
NOTCH • A10402·G
2. Start the piston pin in the piston and the
connecting rod. Using an arbor press, press the
piston pin through the piston and connecting rod
until the end of piston pin is 1.59-3.18mm
(1 / 16-1 /8 inch) below chamfer of the piston pin
bore in the piston.
3. Check the end gap of all partial piston ring set.
End gap must be within specifications. Follow the
instructions contained on piston ring package and
install the partial piston ring set.
4. Check the ring-side clearance of compression A10369·C
rings with a feeler gauge inserted between the
ring and the lower land. Feeler gauge should slide
freely around the ring circumference without Part
binding. Any wear will form a step at the inner Item Number Description
portion of the lower land. If the lower lands 1 - Push Rod Cup (Part of 6500)
have high steps, replace the piston. 2 - Metering Valve Disc
5. Make sure the connecting rod bearing and (Part of 6500)
connecting rod bearing bore in the connecting rod 3 - Check Valve (Part of 6500)
and connecting rod bearing cap are clean. 4 - Plunger Spring (Part of 6500)
Foreign material under the connecting rod 5 - Body (Part of 6500)
bearing will distort the connecting rod bearing and 6 - Check Valve Retainer
cause failure. Install connecting rod bearing in (Part of 6500)
connecting rod and connecting rod bearing cap 7 - Check Valve Spring
with tangs fitting in slots provided. (Part of 6500)
8 - Plunger (Part of 6500)
9 - Lock Spring (Part of 6500)
Assembly
1. Place the plunger upside down on a clean work
bench.
2. Place the check valve (disc or ball check) in
position over the oil hole on the bottom of the
plunger. Set the check valve spring on top of the
check valve (disc or ball check).

ALL RIGHTS RESERVED
03-01C-57 Engine, 7.5L MFI V-8 03-01C-57
3. Position the check valve retainer over the check Assembly

valve and spring. Then, push the retainer down 1. Clean the gasket and seal surfaces of all
into place on the plunger. serviceable parts and assemblies.
4. Place the plunger spring and the plunger (open 2. Position the new cylinder block in a work stand
end up) into tappet body. and install the cylinder head to block dowels and
5. Position the metering valve disc in the plunger, the block drain plugs.
and place push rod cup in the plunger. 3. Transfer all serviceable parts removed from the
6. Depress the plunger and position the closed end old cylinder block.
of lock ring in the groove of the tappet body. With 4. Check all assembly clearances. Refer to
the plunger still depressed, position the open Specifications in this section. Correct as
ends of lock ring in the groove. Release the necessary.
plunger, and then depress it again to fully seat the
lock ring.
7. Use Hydraulic Tappet Leakdown Tester ADJUSTMENTS
TOOL-6500-E or equivalent to fill the valve tappet
with test fluid. Refer to Section 03-00.
Valve Clearance
Cylinder Block Assembly
Disassembly SPECIAL SERVICE TOOL(S) REQUIRED
1. Mount the engine (6007) on a work stand and Description Tool Number
remove all the parts not furnished with the new Tappet Bleed Down Wrench T71 P-6513-B
engine short block (6009).
2. Remove the four cylinder head to block"dowels The valve arrangement on the left bank is E-I-E-I-E-I-E-I
(6A008) and the block drain plugs. and on the right bank is I-E-I-E-I-E-I-E.
3. Remove the old engine short block assembly A 1.52mm (0.060-inch) shorter push rod (6565) or a
from the work stand. 1.52mm (0.060-inch) longer puSh rod is available for
service to provide a means of compensating for
Assembly dimensional changes in the valve mechanism. Refer to
1. Clean the gasket and seal surfaces of all the Master Parts List for the pertinent color code.
serviceable parts and assemblies. Valve stem-to-valve rocker arm clearance Should be
2. Position the new engine short block assembly on within specifications. Refer to Specifications in this
a work stand and install the cylinder head to section. With the hydraulic valve tappet (6500)
block dowels and block drain plugs. completely collapsed, repeated valve reconditioning
operations (valve and lor valve seat refacing) will
3. Transfer all serviceable parts removed from the decrease the clearance to the point that if not
old engine short block. compensated for, the hydraulic valve tappet will cease
4. Check all assembly clearances. Refer to to function and the intake valve (6507) or exhaust
Specifications in this section. Correct as valve (6505) will beheld open.
necessary. The use of a positive stop rocker arm seat bolt
Cylinder Block, Bare eliminates the need for valve clearance adjustment.
However, to obtain accurate valve clearance
Before replacing a cylinder block (6010), determine if measurements, it is important that all components be
it is repairable. If so, make the necessary repairs. serviceable and installed to specification.
To determine whether a shorter or a longer push rod is
Disassembly necessary, perform the following check:
1. Mount the old engine in a work stand and 1. Install an auxiliary starter switch. Crank the
completely disassemble. engine (6007) with the ignition switch in OFF
2. Make sure that cylinder bores are ridge-reamed until the No.1 piston (6108) is on TDC after
before removing piston (6108) and connecting the compression stroke.
rod (6200), if required.
3. Remove the cylinder head to block dowels and
the block drain plugs.

ALL RIGHTS RESERVED
03-0 1C·58 Engine, 7.5L MFI V-8 03-01C-58
2. With the crankshaft (6303) in the positions No. 3 Intake No.4 Exhaust
designated in the following Steps 3, 4 and 5, No. 7 Intake No.5 Exhaust
position the hydraulic tappet compressor Tappet
Bleed Down Wrench T71 P-6513-B on the rocker No. 8 Intake No.8 Exhaust
arm (6564). Slowly apply pressure to bleed down 4. After checking the clearance on these intake
the hydraulic valve tappet until the plunger is valves and exhaust valves, rotate the crankshaft
completely bottomed. Hold the valve tappet in 360 degrees to Position No.2, then check the
this position and check the available clearance following valves:
between the rocker arm and the valve stem tip
with a feeler gauge. If the clearance is less than No. 2 Intake No.2 Exhaust
specifications, install a shorter push rod. If the No. 4 Intake No.3 Exhaust
clearance is greater than specifications, install a No.5 Intake No.6 Exhaust
longer push rod.
TIMING
POINTER
6023
POSITION 1 - NO.1 AT TOe AT END OF COMPRESSION STROKE.

(ONE REVOLUTION) CLOCKWISE FROM POSITION 1.
A7108-B
3. With the No. 1 piston at TOe at the end of the

compression stroke (Position No.1), check
clearances on the following valves:
SPECIFICATIONS
GENERAL SPECIFICATIONS
011 Pressure Engine Type
Hot @ 2000 rpm and Number of
Engine Bore and Stroke Firing Order kPa (psi) Cylinder
7.5L (460 CID) V-8 4.36x 3.85 15426378 276-606 (40-88) O.H.V. V-8
CYLINDER HEAD AND VALVE TRAIN

Valve Guide Valve Seal
Bore Diameter Wldth 8
Combustion
Chamber Valve Seat Valve Gasket
Volume RunoutTIR Arrangement Surface
Engine C.C. b Intake Exhaust Intake Exhaust Maximum Front to Rear FlatnessC
7.5L (460 CIO) V-8 89.5-92.5 .3433-.3443 .3433-.3443 .060-.080 .060-.080 .002 RT I-E-I-E-I-E-I-E .003 in Any
LT E-I-E-I-E-I-E-I 61n.
.006
Overall
b Compression pressure (psi) of the lowest cylinder must be at least 75% of the highest to be within specification.
c Gasket surface finish - RMS 60-150.
ALL RIGHTS RESERVED
03-01C-59 Engine, 7.5L MFI v-a 03-01C-59
CYLINDER HEAD AND VALVE TRAIN (Continued)

Collapsed Tappet Gap
Valve Tappet or Lifter (Clearance)
Hydraulic
Rocker Lifter
Arm Lift Push Rod Runout TIR Standard Clearance Leak-Down
Engine Ratio to 1 Maximum Diameter to Bore8 Rate b Allowable De.lred
7.5L (460 elD) V-8 1.73 .015 .8740-.8745 .0007-.0027 10t050 .075-.175 .100-.150
Seconds
for 1/16
Travel
b Time required for plunger to leak-down .0625 in. under load of 50 Ibs. using leak-down fluid in tappet.

Valve Spring Compression
Pressure Lbs. Valve Spring Free Valve Spring
@ Specified Height Length (Approximate) Assembled Height
Valve Spring Out of
Engine Intake8 Exhaust Intake Exhaust Intake Exhaust Square Maximum
7.5L (460 CID) V-8 76-84@ 1.81 76-84@ 1.81 2.06 2.06 1.78-1.84 1.78-1.84 5/64 (.078)
218-240 218-240
@ 1.33 @ 1.33
a Service limit - 100/0 loss of pressure.

Valve Stem to Guide Clearance 8 Valve Head Dlameter b
Valve Face Runout TIR
Engine Intake Exhaust Intake Exhaust Maximum
7.5L (460 CID) V-8 .0010-.0027 .0010-.0027 2.075-2.090 1.646-1.661 .002
a Service clearance - .0055.
b Valve face angle - 44 0 •

Valve Stem Diameter
Engine Intake I Exhaust Intake I Exhaust Intake I Exhaust
7.5L (460 CID) V-8 .3415-.3423 I .3415-.3423 .3565-.3573 I .3565-.3573 .3715-.3723 I .3715-.3723
CAMSHAFT
8
Lobe Llft Camshaft End Play
Camshaft Journal to
Engine Intake Exhaust End Play Service Limit Bearing Clearance b
7.5L (460 CIC) V-8 .252 .278 .001-.006 .009 .001-.003
CAMSHAFT DRIVE
Camshaft Journal Diameter - Standard- Camshaft Bearing Inside Diameter
nmlng
Camshaft Chain
Front Deflection
Bearing Inches
Engine No.1 No.2 No.3 No.4 No.5 No.1 No.2 No.3 No.4 No.5 Locatlon b Maximum
7.5L (460 CID) 2.1238- 2.1238- 2.1238- 2.1238- 2.1238- 2.1258- 2.1258- 2.1258- 2.1258- 2.1258- .040-.060 .500
v-a 2.1248 2.1248 2.1248 2.1248 2.1248 2.1268 2.1268 2.1268 2.1268 2.1268
b Distance in inches that front edge of the bearing is installed below the front face of the cylinder block.

ALL RIGHTS RESERVED
03-01C-60 Engine, 7.5L MFI v-a 03-01C-60
CYLINDER BLOCK
Distributor Head Gasket
Cylinder Bore Main Bearing Shaft Bearing Surface Head Gasket Tappet Bore
Engine Dlameter8 Bore Diameter Bore Diameter Flatness Surface Finish Diameter
7.5L (460 CIC) V-8 4.3600-4.3636 3. 1922-3. 1934 .5160-.5175 .003 in Any 6 In. RMS90-150 .8752-.8767
.006 Overall
a Maximum out-of-round - .0015, service limit - .005, maximum taper service limit - .010, cylinder bore surface finish RMS 18-38, Bore
taper service limit - .010.

Main Bearing Main and Rod
Main Bearing Main Bearing Journal Thrust Bearing Main Bearing
Main Bearing Journal Thrust Face Taper Bearing Journal Thrust Face
Journal RunoutTIR RunoutTIR Maximum Per Journal Finish RMS Finish RMS
Engine Dlameter8 Maxlmum b Maximum Inch Length Maximum Maximum
7.5L (460 CID) V-8 2.9994-3.0002 .002 .001 .0005 1. 124-1. 126 12 25 Front - 23
Rear

Connecting Rod Journal Connecting Rod Journal Taper
Engine Dlameter8 Per Inch Maximum Crankshaft Free End Playb
7.5L (460 CIC) V-8 2.4992-2.5000 .0006 .004-.008

Connecting Rod Bearing to Crankshaft Clearance
Selective Fit Main Bearing to Crankshaft Clearance Selective Fit
Engine Desired Allowable Thickness Std. 8 Desired Allowable Thickness Std. 8
7.5L (460 CtC) .0008-.0015 .0008-.0025 .0757-.0762 Main Bearing Cap Main Bearing Cap .0955-.0960
V-8 2,3,4,5: 2,3,4,5:
.0009-.0027 .0009-.0027
Main Bearing Main Bearing
Cap: Cap:
.0004-.0022 .0004-.0022
CONNECTING ROD, PISTON AND RINGS

Connecting Rod Alignment
Maximum Total Difference
Rod to
Crankshaft
Piston Pin Bore or Rod Bearing Bore Rod Length Assembled Side
Engine Bushing I.D. I.D. 8 Center of Center Twlstb Bend b Clearancec
7.5L (460 CID) V-8 1.0386-1.0393 2.6522-2.6530 6.6035-6.6065 .024 .012 .010-.020
a Connecting rod bearing bore maximum out-of-round - .0004.
b Pin bushing and crankshaft bore must be parallel and in same vertical plane within specified total difference when measured at the ends
c Service limit - .023.
CONNECTING ROD, PISTON AND RINGS (Continued)

Diameter
To Piston Pin Bore To Connecting Rod
Engine Length Standard .001 Oversize Clearance 8 Bushing Clearance
7.5L (460 CtC) V-8 3.290-3.310 1.0398-1.0403 1.04 10-1 .04 13 .0002-.0005 Interference Fit
a Selective Fit.

ALL RIGHTS RESERVED
03-01C-61 Engine, 7.5L MFI v-a 03-01C-61
CONNECTING ROD, PISTON AND RINGS (Continued)

Ring Width Side Clearance- Ring Gap
Compression Compression Compression (In Gauge)
Engine Top Bottom Top Bottom 011 Top Bottom 011
7.5L (460 CID) .0773-.0783 .0773-.0783 .0012-.0022 .0012-.0022 Snug .010-.015 .011-.021 .010-.030
V-8
PISTON
Diameter- Ring Groove Width Compression
Piston to
Bore
Clearance Piston Pin
.003 Selective Bore
Engine Coded Red Coded Blue Oversize Fit Diameter Top Bottom 011
7.5L (460 CID) 4.3585-4.3595 4.3595-4.3605 4.3605-4.3615 .0014-.0022 1.0401-1.0406 .0795-.0805 .0795-.0805 .1586-
V-8 .1596
a Measured at the piston pin bore centerlin~ at 90° to the pin.
PISTON (Continued)
I.D.Codeof
Service Piston
Piston Bore Diameter Required
110.744-110.774mm (4.3600-4.3612 In.) Red
110.774-110.805mm (4.3612-4.3624 In.) Blue
110.805-110.835mm (4.3624-4.3636 In.) Yellow
When replacing pistons, measure cylinder bore as

described in General Gasoline Engine Service, Section
21-01. Install service piston matched in piston bore
diameter above.
LUBRICATION SYSTEM
Engine 011 Capacity·
Relief Valve
Spring Relief Rotor Outer Inner to
Pressure Lbs. Drlveshaft Valve to Assembly Race to Outer
@Speclfled to Housing Housing End Housing U.S. Imperial Rotor Tip
Engine Length Clearance Clearance Clearance Clearance Qts. Qts. Liters Clearance
7.5L (460 CID) 20.6-22.6 .0015-.0030 .0015-.0030 .004 .001-.013 5 4.2 4.7 .012
V-8 @2.49 Maximum
a Add 1 U.S. quart (or equivalent in Imperial quarts or liters) when replacing filter.
DRIVE BELT TENSION

Used Belt Tension
New Belt Tension (Greater Than 5 Min. Min. Tension After 5
Engine Tensioning Method Belt Type (0 Min. Operation) Operation) Min. Operation
7.5L (A/C and PIS Belt) 6K Poly-V Belt Tension OK if tensioner Same As New Same As New
. Automatic within indicator marks.
418 N (94 Lb.) Min.
7.5L (Alt and Air Pump Belt) 6K Poly-V Belt 711-889 N 489-578 N 467 N (105 Lb.)
Manual (160-200 Lb.) (110-130 Lb.)

ALL RIGHTS RESERVED
03-01C-62 Engine, 7.5L MFI v-a 03-01C-62

Description H·m Lb-Ft Description H·m Lb-Ft
Frame Bracket Attaching Bolt Bolt, 3/8-16 x 2.75, Exhaust 52-65 38-48
Locknuts 58-77 34-57 Crankshaft Pulley Bolts 54-71 40-53
Nut, Insulator-to-Support Mounting Fan Blade-to-Fan Clutch Bolts 16-24 12-18
Bracket (F-250, F-350 and F-Super
Duty) 109-149 80-109 Alternator / Air Pump
Bracket-to-Head Bolt (7 / 16 Inch) 53.1-71.9 40-53
Insulator-to-Engine Bolts 81-109 60-80
Fan Clutch-to-Water Pump Pulley 16-24 12-18
Insulator-to-Support Bracket Nuts
(F-Super Duty Motorhome Chassis) 96-127 71-94 Generator / Air Pump
Bracket-to-Head, Block and Water
Nut and Washer Assembly, Pump Bolts (3/8 inch) 40.3-54.7 30-40
Insulator-to-Support Bracket
(F-250, F-350 and F-Super Duty 87.5-118.5 64-87 Generator Adjusting Arm Bolts 40.3-54.7 30-40
Nut, Support Bracket-to-Frame 58-77 43-57 EGR Valve-to-Exhaust Manifold

Tube 34-65 25-48
Rocker Arm Seat Bolts 25-34 18-25
Generator Pivot Bolt 53.1-71.9 40-53
Cylinder Head Attaching Bolts - in
Sequence: Generator Locking Bolt
Step 1 95-108 70-80 (Med. and Lg. Frame Alt.) 40.3-54.7 30-40
Step 2 136-149 100-110 Generator Locking Bolt
Step 3 176-189 130-140 (Sm. Frame Alt.) 40.3-54.7 30-40
Muffler Inlet Pipe Stud Nuts 34-49 25-36 Air Pump Pivot Bolt 40.3-54.7 30-40
Water Pump-to-Engine Front Cover Air Pump Locking Bolt 40.3-54.7 30-40
Bolts 16-24 12-18 Air Pump Pulley Bolts 11.4-15.6 9-11
Camshaft Sprocket Capscrew 54-68 40-50 AC / PS Bracket-to-Water Pump
Engine Front Cover-to-Cylinder Stud Nut 40.3-54.7 30-40
Block Attaching Screws 16-24 12-18 AC / PS Bracket-to-Head Bolts 53.1-71.9 40-53
70-105 PS Pump-to-Bracket Bolts 40.3-54.7 30-40
Engine Front Cover-to-Oil Pan Bolts 8-12 (Lb-In)
Drive Belt Tensioner Bolt 68-92 50-68
Crankshaft Vibration
Damper-to-Crankshaft Attaching AC Compressor Bolts 23.3-31.7 18-23
Bolt 95-122 70-90 AC Idler Bolts 23.3-31.7 18-23
Camshaft Thrust Plate-to-Cylinder 90-135 Oil Gallery Plugs, 3/8-18 31-38 23-28
Block Bolts 11-15 (In-Lb)
Valve Cover Bolts, 1/4-20 12-15 9-11
Flywheel-to-Crankshaft Mounting
PCV Valve Body 13-26 10-19
Bolts 103-115 75-85
Oil Filter Mounting Insert 61-203 45-150
Oil Pump-to-Cylinder Block
Attaching Bolts, Nut 30-43 22-32 Engine Oil Cooler Bolt 54-88 40-65
Oil Pump Screen Cover and 27-35
Tube-to-Oil Pump Bolts 16-24 12-18 Engine Oil Cooler Hose Clamp 3-4 (Lb-In)
Oil Pump Screen Cover and 15-25
Tube-to-Main Bearing Cap Nut 30-43 22-32 Radiator Lower Hose Clamp 1.6-2.8 (Lb-In)
Oil Lever Indicator Tube Nut 13-24 10-18 Oil Pressure Sender 11-24 8-18
Engine Rear Plate Bolts 54-75 40-55 Spark Plug 7-14 5-10
Engine Lifting Eye Bolts 54-75 40-55 Upper Intake Manifold-to-Lower
Intake Manifold Bolts 16-24 12-18
Oil Pan-to-Cylinder Block Attaching
Bolts Lower Intake
1/4-20 11-16 8-12 Manifold-to-Cylinder-Head Bolts
129-142 95-105 and Nuts - in Sequence:
Crankshaft Main Bearing Cap Bolts
Step 1 11-16 8-12
Connecting Rod Bearing Cap Nuts 61-68 45-50
Step 2 16-30 12-22
Exhaust Manifold Bolts and Studs 52-65 38-48 Step 3 30-47 22-35
Locknut, Spark Plug Heat Shield 13-24 10-18
(Continued)
1995 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivet.rain July 1994

ALL RIGHTS RESERVED
03·01C·63 Engine, 7.5L MFI V-8 03·01C-63
TORQUE LIMITS - 7.5L (460 CID) MFI V-8 ENGINE

NOTE: All values are In N·m (lb-ft) unless otherwise noted. 011 threads with engine 011 unless the
threads require 011 or water-resistant sealer. The standard torque limits listed below are applicable
for all functions not listed in the special torque chart.
1/4-20 5/16-18 5/16-24 3/8-16 3/8-24 7/16-14 7/16-20 1/2-13 9/16-18
S-12 16-24 19-27 30-43 37-52 54-75 54-75 75-10S 115-163
(6-9) (12-1S) (14-20) (22-32) (27-3S) (40-55) (40-55) (55-80) (85-120)
PIPE THREADS SPECIAL SERVICE TOOLS REQUIRED (Cont'd)

1/8-27 1/4-18 3/8-18 1/2-14 Tool Number1
Description Illustration
7-11 11-16 16-24 16-24
(5-8) (S-12) (12-1S) (12-18) T58P-6316-D
SPECIAL SERVICE TOOLS/EQUIPMENT ~ TI8P-e31I-D
SPECIAL SERVICE TOOLS REQUIRED TOOL-6331-E
Tool Number1
T70P-6000
Description
Engine Lifting Brackets

illustration
Main Bearing Insert Tool
e:::v TOOL-I331-E
~~ TOOL-6500-E
~
Hydraulic Tappet Leak-Down
Tester
T7GP-IOOO
T6SP-60 19-A TOOL...5OO-E
~
Front Cover Aligner
T71 P-6513-B
Tappet Bleed Down Wrench
0
TIIP-I01..A
T71 P-6565-A
~~
T71P~113-8
T74P-6666-A
~
Spark Plug Wire Remover
T68P-6135-A
O~®foo~
T74P......A
T70P-6B070-B
Front Cover Seal Replacer
tl
-A1 -147 -AJ. -AI -M -AI -M
TIIP~1"A
TSST-6701-A ~8070-8
~
Crankshaft Seal
Replacer / Cover Aligner T65L-6250-A
Camshaft Bearing Set
( E:J )
T52L-6306-AEE
T"T~701-A
ii2iiikE ~
•
• •~ G)G>0°
Crankshaft Damper and
~
Sprocket Replacer TIIL..2IO-A
TOOL-4201-C
(Continued)
TI2L. . . .AEE Dial Indicator with Bracketry
I TOOL-4Z01-e
ALL RIGHTS RESERVED
03-01C-64 Engine, 7.5L MFI v-a 03-01C-64

(Continued)
SPECIAL SERVICE TOOLS DESIRED ROTUNDA EQUIPMENT
Tool Number Description Model Description

D87L-9280-A Spring Lock Coupling Disconnect Tool 077-00008 Low Lift Transmission Jack
(3/8 Inch)
014-00293 Gear and Pulley Puller
D87L-9280-B Spring Lock Coupling Disconnect Tool
014-00282 Dial Indicator with Bracketry
(1/2Inch)
ALL RIGHTS RESERVED
03-010-1 Engine, Diesel, 7.3L V-8 03-010-1
SECTION 03-010 Engine, Diesel, 7.3L v-a

VEHICLE APPLICATION ...•..••••••••••.•.......••••••••.•....••••03-01 D-1 DESCRIPTION AND OPERATION ..•••..•..•••..•.•••••••••.••.03-01 D-1
VEHICLE APPLICATION
Vehicles Equipped with 7.3L DI Diesel Engine
Refer to the 1995 7.3L DI Diesel Engine Supplement

for service information.

ALL RIGHTS RESERVED
03·03·1 Engine Cooling 03·03·1
SECTION 03·03 Engine Cooling

VEHICLE APPLICATION ••••••••••••••••..••••••••••••••••••••••••••• 03·03·1 REMOVAL AND INSTALLATION (Cont'd.)
DESCRIPTION AND OPERATION Engln. Block H.at.r •••••••••••••••••••••••••.••.•••••••••.••.•• 03·03·40
Coolant and Suppl.m.ntary Coolant . Engln. Coolant T.mp.ratur. S.nsor•••••••.••••.••••••. 03·03·37
Addltlv.s •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 03·03·3 Radiator •••••••••••••••••••••••••••••••••••••••••.••.•••••.••••••••••• 03-03·19
Approv.d Coolant and Conc.ntratlon ••••••••••••••••• 03-Q3·3 Radiator Coolant R.cov.ry R.s.rvolr••••••.•••••••.•••• 03·03·28
Coolant Disposal •••••••••••••••••••••••••••••••••••••••••••••••• 03·03·4 Radiator Dralncock •••••••••.•••••.•.•••••••••••••••••••••••••••• 03-03·34
Unsatisfactory Coolant Mat.rlals and Aluminum Cor. Radiator ••••••.••••••••••••••••.••.•••••.•. 03.03.34
Suppl.m.ntary Coolant Addltlv.s •••••••••••••••••.• 03·03·4 Copp.rIBrass Radiator •••.•••••••••••••••••••••••••••••••• 03·03·35
Coolant R.cov.ry Syst.m ••••••••••••••••••••••••••••••••••••.• 03·03·4 Radiator Hos.s •••••••.••••••••••••••••••.••••••••••••••••••••••••• 03-03·17
Cooling Fan and Clutch •••••••••••••••••••••••••••••••••••••••••• 03·03·6 Upp.r and Low.r •••••••••••••••••••••.•..••••••••.•••••••••••• 03-03·17
Cooling Syst.m ••••••••••••••••••••••••••••••••••••••••••••••••••••• 03·03·1 Th.rmostat, Wat.r ••••••••••••••••••••••••••••••••••••••••••..••• 03.03.15
EI.ctrlcal Syst.m•••••••••••••••••••••••••••••••••••••••••••.••••••• 03·03·4 Wat.r Inl.t •••••••••••.•••••••••••••••••••.•.•.••••.•••••.••••••••••.• 03-03·19
Engln. Block H.at.r •••••••••••••••••••••••••••••••••••••••••••••• 03-03·6 Wat.r Pump ••••••••••••••••••••••.•.••••••••••••••.•••••••.•...••••• 03-03·16
Engln. 011 Cool.r ••••••••••••••••••••••••••••••••••••••••••••••••••• 03·03·6 Wat.r T.mp.ratur. Indicator S.nd.r
Radiator •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 03·03·4 Unit ••••••..•••••••••••••••••••••••••••••••••••.••••.••••••••••••••••• 03-03·35
Aluminum Cor. Crossflow •••••••••••••••.••••...••.•••••••• 03·03·4 Wat.r T.mp.ratur. Indicator S.nd.r
Aluminum Cor., Downflow•••••••••••••••••••••••••••••••••• 03·03·4 Unit .•••••••••••••••••••••••••••••••.•••••.•••••••••••.••••.•••••••.••03·03-37
Copp.r Cor., Downflow ••••••••••••••••••••••••••••••••••••• 03-03·5 SERVICE PROCEDURES
Th.rmostat, Wat.r ••••••••••••••••••••••••••••••••••••••••••••••••. 03-03·6 Radiator Cor. and Tank S.rvlc.,
DIAGNOSIS AND TESTING Copp.rIBrass Radiators •••••••••.••••••••••••.••••••••••• 03·03·41
Compon.nt T.sts •••••••••••••••••••••••••••••••••••••••••••••••• 03·03·12 Radiator Tank Flang•••••••••••••••••••••••••••••••••••••••.•••• 03-03·41
Pr.ssur. T.st •••••••••••••••••.••••••••••••••••••••••••••••••••• 03-03·12 Transmission 011 Cool.r Connection
Radiator Cap Pr.ssur. T.st •••••••••••••••••.••••••••.••• 03·03·13 L.aks ••••••••.••••••••••.••••••••••••.•••••••••••..•.•••••••.••••••• 03·03·41
Radiator L.ak T.st, R.mov.d from CLEANING AND INSPECTION
V.hlcl••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 03·03·14 Coolant Condition Ch.ck ••••••••••••••••••••••••••••••••••••• 03·03·41
Th.rmostat, Wat.r ••••••••••••••••••••••••••••••••••••••••••• 03·03·14 Cooling Syst.m Hos.s and Clamps•••••••••••••••••••••• 03-03·42
EI.ctrlcal Sch.matlcs ••••••.••••••••••••••••••••••••••••••••••••• 03·03·7 Cooling System, CI.anlng •....•••••••••••••.••••.•••••••••••• 03-03·43
Fan Clutch T.st••••••••••••••••••••••••••••••••••••••••••••••••••••03·03·14 Cooling Syst.m Flush Proc.dur••••...•••••••••••••••• 03·03·43
Dls.ngag.d Fan Clutch R.qulr.m.nt T.st - Radiator Install.d •••••.••••..•••••••..•.•.••••••••••••••••• 03-03·43
Cold •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 03·03·14 Cooling Syst.m, Draining, Filling and
Maximum Sp••d Fan Clutch R.qulr.m.nt Ble.dlng •.••••••••••••••••••.••••.••••••••••••••••••••••••••••••••03-03·43
T.st ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••.• 03-03·14 Fan Blade •••••••••••••••••.•••••••••..••••••••••••••••.•••••••..••••• 03-03·45
Insp.ctlon and V.rlflcatlon •••••••••••••••••••••••••••••••••••• 03-03·7 Radiator ••••••••••••••••••••••••••••••••••.••••••••••.•••••••••••••••• 03·03·45
Pinpoint T.sts ••••••••••••••••••••••••••••••••••••••••••••••••..••••• 03·03·8 Radiator Cap ••••••••••••••••••••••••••••••••••••••••••••••••••••••• 03-03·44
Symptom Chart•••••••••••••••••••••••••••••••••••••••••••••••••••••• 03·03·8 Radiator Coolant L.v.1 Ch.ck •.••••..•••.•••••••.•••••••••• 03-03·41
REMOVAL AND INSTALLATION SPECIFICATIONS
Bypass Hos••••••••••••••.•••••••••••••••••••••••.•••••••••••••••••• 03·03·17 Coolant Mlxtur••••••••••••••••••.•••••••••••••••••••••••••.••••••• 03·03·46
Cabl., EI.ctrlcal, Engln. Block H.at.r ••••.•••••••••••• 03·03·37 Cooling Syst.m Part Numb.rslApplication
Constant T.nslon Hos. Clamp •••••••••••••••••••••••••••••03-03·16 Chart••••••••••••••••••••••••••••.•••.•••••••....•.•.••••••••.••••••• 03·03·46
Cooling Fan Blad. and Fan Clutch, SPECIAL SERVICE TOOLSIEQUIPMENT •••••••••••••••••• 03-03·48
M.chanlcal••••••••••••••••••••••••••••••••••••••••••••••••.•••••• 03·03·31
VEHICLE APPLICATION
F-150, F-250, F-350, F-Super Duty, Bronco Vehicles
and F-250, F-350 and F-Super Duty Vehicles with
7.3L Diesel Engines
Cooling System
This section covers cooling system diagnosis and
service, cooling system component removal,
disassembly, assembly, installation, service
procedures and specifications.
ALL RIGHTS RESERVED
03-03-2 Engine Cooling 03-03-2
WARNING: DO NOT STAND IN LINE WITH OR • Pressure-vacuum radiator cap, allows coolant to
NEAR RADIATOR FAN BLADE (8600) WHEN escape to coolant recovery reservoir when it
ENGINE (6007) IS RUNNING. expands so system pressure does not build,
WARNING: NEVER REMOVE THE RADIATOR CAP possibly bursting a hose or radiator tube. The
(8100) UNDER ANY CONDITIONS WHILE THE radiator cap allows coolant to be drawn back in
ENGINE IS OPERATING OR WHEN THE COOLING from coolant recovery reservoir when system
SYSTEM IS HOT. FAILURE TO FOLLOW THESE cools, refilling system and preventing hoses from
INSTRUCTIONS COULD RESULT IN DAMAGE TO collapsing from a partial vacuum in system. The
THE COOLING SYSTEM OR ENGINE OR pressure-vacuum radiator cap also maintains
PERSONAL INJURY. TO AVOID HAVING SCALDING 90kPa (13 psi) pressure in the cooling system.
HOT COOLANT OR STEAM BLOW OUT OF THE Pressurizing the cooling system raises the boiling
RADIATOR (8005), USE EXTREME CARE WHEN temperature of the coolant allowing more efficient
REMOVING THE RADIATOR CAP FROM A HOT higher engine temperatures and reducing the risk of
RADIATOR. WAIT UNTIL THE ENGINE HAS boiling over when driving at high altitudes.
COOLED, THEN WRAP A THICK CLOTH AROUND • Engine cooling fan, draws air through the radiator to
THE RADIATOR CAP AND TURN IT SLOWLY TO help cooling at low speeds or when the vehicle is not .
THE FIRST STOP. STEP BACK WHILE THE moving. The system is designed so that air forced
PRESSURE IS RELEASED FROM THE COOLING through the radiator by the forward motion of the
SYSTEM. WHEN YOU ARE SURE ALL THE vehicle is sufficient at driving speeds.
PRESSURE HAS BEEN RELEASED, PRESS DOWN • Fan clutch (8A616), allows fan to spin freely when
ON THE RADIATOR CAP (STILL WITH A CLOTH), engine is cold or when air forced through the
TURN AND REMOVE IT. radiator by the vehicle's motion is sufficient to cool
Components it. This saves engine power and helps speed
warm-up. The fan clutch has a thermostatic control
The cooling system consists of: so that it drives the fan when the engine is hot and
• Coolant, consisting of ethylene glycol anti-freeze air from the vehicle's motion is insufficient.
and water. Carries excess heat from engine to • Drive belt (8620), drives the water pump, fan and
radiator where the excess heat is transferred to the other accessories off of engine crankshaft (6303).
surrounding air. Refer to Section 03-05 for more information on drive
• Radiator, allows excess engine heat to be belt.
transferred to the air. • Engine transmission fluid cooler (7A095). On
• Radiator hoses which attach radiator to engine. vehicles with automatic transmissions, a provision
is made for cooling the transmission oil by
• Water pump (8501) which circulates coolant circulating running it through a cooler in the radiator.
through system.
• Engine oil cooler (6A642). On smaller engines, the
• Passageways cast into the cylinder block (60 10) oil coming in contact with the engine block walls,
and cylinder heads (6049) which allow coolant to which contain coolant passageways, is sufficient for
circulate and absorb excess heat so that engine cooling engine oil.
parts are not damaged by excess heat.
• Heater water hose (18472) and heater core
• Water thermostat (8575) which controls coolant (18476). The heater or climate control system uses
temperature, allowing quicker engine warm-up engine heat to heat the passenger compartment of
improving fuel economy and reducing pollution. the vehicle. On vehicles with standard heaters,
• Bypass hose or passageway which allows coolant coolant circulates through the heater core
to circulate within the engine when the water whenever the engine is running. Heater output
thermostat is closed preventing hot spots. controlled by air door function. On vehicles with air
conditioning systems, a valve controlled by the A/C
• Coolant recovery reservoir holds surplus coolant. system may control coolant flow to the heater core.
When the system is hot and coolant expands,
Refer to Group 12 in the Body, Chassis manual for
coolant goes into coolant recovery reservoir. When
further information.
the vehicle cools, the system draws coolant back
into the radiator, eliminating the need for frequent Coolant Flow
"topping-off" of the cooling system. The coolant
Coolant flows from the radiator through the lower
recovery reservoir eliminates the loss of coolant
radiator hose to the engine-driven water pump. This
through an overflow tube.
pump forces the coolant through the engine oil cooler
• Degas Bottle (F-Series R / C) removes air and (if equipped), engine block and cylinder passageways.
combustion gasses from the coolant. This maintains If the thermostat is closed, coolant returns to the
efficient heat transfer capability in the coolant. water pump through the bypass hose or a bypass
passageway in the engine. If the thermostat is open,
the coolant passes back into the radiator where air
passing over the radiator tubes removes the excess
heat.
ALL RIGHTS RESERVED
03-03-3 Engine Cooling 03-03·3
Engine Coolant Flow~ 'l.3L Diesel Coolant and Supplementary Coolant

Additives
Approved Coolant and Concentration
The approved coolant for Ford vehicles is a 50/50
mixture of water and Ford Premium Cooling System
Fluid E2FZ-19549-AA or 8 or equivalent meeting
specification ESE-M97844-A, plus 1.5 quarts of
Heavy Duty Cooling System Additive FW-15 or
ESN-M998169-A.
This coolant mixture:
.,
VIEW A
• Provides antifreeze protection down to -28.8 to
-37.2 degrees Celsius (-20 to -35 degrees
Fahrenheit).
• Provides protection against boil over to a system
temperature of 120 degrees Celsius (250 degrees
Fahrenheit). Too high a concentration of antifreeze,
while allowable in extremely cold climates, may
cause overheating in hot weather as antifreeze
cannot absorb and reject heat as well as water.
• Provides corrosion protection, as coolant meeting
Ford specification ESE-M97B44-A and
ESE-M97B43 contains additives to fight scale and
corrosion.
• Provides proper water pump lubrication. Too Iowa
concentration of antifreeze may cause water pump
failure.
The acceptable concentration ranges for all climates
are: (minimum) 45% antifreeze to 55% water and
(maximum) 60% antifreeze to 40% water.
Use only a hand-held refractometer, Rotunda Optical
Antifreeze / Battery Tester 021-00046 or equivalent to
verify coolant concentration.
VIEW A Ordinary tap water may be used for a brief time in an
Q4733-A emergency 'unless the water is known to be
exceptionally hard or high in alkali content. As soon as
possible, the system should be drained and flushed
Part and the ~roper mixture of water and Ford Premium
Item Number Description Cooling System Fluid E2FZ-19549-AA or 8 or
1 8005 Radiator
equivarent meeting specification ESE-M97844-A, plus
2 8075
1.5 quarts of Heavy Duty Cooling System Additive
Radiator Overflow Hose FW-15 or equivalent meeting Ford specification
3 8575 Water Thermostat ESN-M998169-A.
4 8A080 Radiator Coolant Recovery
Reservoir CAUTION: Failure to use Heavy Duty Cooling
5 8592 Water Hose Connection System Additive FW-15 or an eguivalent meeting
6 6019 Engine Front Cover
Ford specification ESN-M99B169-A could result
in premature engine breakdown.
9 6731 Oil Filter
10 6A642 Oil Cooler
11 6A051 Block Heater
12 8592 Water Hose Connection
13 8501 Water Pump
14 8100 Radiator Cap
15 8A020 Degas Bottle
ALL RIGHTS RESERVED

Unsatisfactory Coolant Materials and
Supplementary Coolant Additives Radiator
The following are NOT authorized for use in Ford NOTE: For aluminum core (downflow-type or
vehicles: crossflow-type) radiator assemblies, the tanks and / or
transmission oil cooler must not be removed from the
• Recycled coolant. Tests run by Ford Motor radiator for service or repair. Replace the complete
Company indicate that recycled coolant does not radiator assembly instead of plastic tank removal from
meet required specifications ESE-M97B44-A and the radiator.
ESE-M97843-A.
Aluminum Core Crossflow
• Alcohol-type antifreeze. Alcohol-type antifreeze
Vehicles with the 4.9L, 5.0L, 5.8L and 7.5L engines
does not provide adequate water pump lubrication
use a cross-flow type radiator (8005). In this type
and, having a lower boiling point than water, boils off
radiator, coolant flows horizontally from a radiator inlet
reducing anti-freeze protection.
tank (8079) to a radiator outlet tank (8054). On
• Alkali or calcium chloride solutions or water vehicles with automatic transmissions, the radiator
containing a high alkali content. These solutions will outlet tank also includes a transmission oil cooler.
cause serious engine and cooling system damage,
The core is of aluminum tube- and fin-type. Controlled
especially in systems containing aluminum
atmosphere brazed (CAB) to the headers. The tanks
radiators, cylinder heads, or other components.
are fiberglass-reinforced nylon, and are designed to
• Propylene Glycol-type coolant. Propylene allow for even distribution of coolant among the tubes.
Glycol-type coolants provide less heat transfer and
some may not provide enough corrosion protection. Typical Crossflow (Horizontal) Radiator
Coolant Disposal
When disposing of used coolant, always do so in
accordance with all applicable federal, state, and local
laws and regulations. Note that anti-freeze is toxic to
humans and animals.
Electrical System
Except for the coolant temperature gauge and water
temperature indicator sender unit (10884), and the
engine coolant temperature sensor (ECT
sensor)( 12A648), there are no electrical components
in the cooling system. Refer to Group 13 for
information on the temperature gauge.
Coolant Recovery System Aluminum Core, Downflow

NOTE: Walter C. Avrea, the owner of patents 3,601, Vehicles equipped with the 7.3L diesel engine use a
181 and RE27, 965, has granted Ford Motor downflow-type radiator. This radiator is designed so
Company rights with respect to cooling systems that coolant flows down from a top coolant tank,
covered by these patents. through the cooling tubes and into the bottom cooling
tank.
The coolant recovery system consists of the:
The radiator core is of the aluminum tube- and fin-type.
• Radiator coolant recovery reservoir (8A080) Tubes are controlled atmosphere brazed (CAB) to the
• Radiator overflow hose (8075) headers.
• Pressure-vacuum radiator cap (8100) The tanks are fiberglass-reinforced nylon and are not
removable for radiator service. The tanks are
For descriptions, refer to Cooling System in this designed to provide for even distribution of the coolant
section. among the radiator tubes.
The advantages of a coolant recovery system are: On vehicles with automatic transmissions, the radiator
• No loss of coolant when engine is hot. outlet tank also contains a transmission oil cooler.
• Reduced pollution due to coolant not being released
from the vehicle.
• Reduced air trapped in the coolant resulting in less
overheating from coolant foaming, longer water
pump seal life, reduced possibility of water pump
impeller damage from bubbles in coolant, longer
hose life, and less cooling system corrosion.
ALL RIGHTS RESERVED
7.3L Diesel Radiator, Typical

Part
3 - Filler Neck (Part of 8079)
4 - Overflow Outlet
(Part of 8079)
5 - Lifting Eye (Part of 8005)
6 - Support Straps
(Part of 8005)
7 8054 Outlet Tank (Part of 8005)
8 - Transmission Oil Cooler
Connections (Part of 8054)
9 - Inlet (Part of 8079)
10 8115 Draincock
11 - Outlet (Part of 8054)
12 - Core (Part of 8005)
Copper Core, Downflow

Some 7.3L engines are equipped with copper core
downflow radiators. The 7.3L engine copper core
radiator is being phased out by an aluminum radiator
during 1995 assembly. The radiators consist of a core
of copper tubes and fins, with stamped brass upper
and lower tanks soldered to the core headers and
steel side reinforcements. On vehicles with automatic
transmissions, a transmission oil cooler is installed in
the bottom tank.
Hot coolant from the engine (6007) enters the upper
tank which distributes it through the tubes. The
coolant exits from the bottom tank to the water pump
(8501).
The copper core radiator should be sent to an
experienced radiator specialty shop for repairs or the
radiator replaced as an assembly. The tanks, core,
and transmission oil cooler are not available
separately from Ford.
Q1714-F
Part
1 - Lifting Eye (Part of 8005)
2 8079 Inlet Tank
(Continued)
ALL RIGHTS RESERVED
Typical Downflow Radiator The fan is driven through a viscous-type fan clutch
(8A616) which is controlled by an integral bimetal
TYPICAL COPPER CORE DOWNFLOW RADIATOR thermostat.
Thermostat, Water
A poppet-type water thermostat (8575) is used with
all engines (6007).
When the water thermostat is closed, coolant flows to
the water pump (8501) through a bypass passage at
the front of the engine. When the water thermostat is
open, coolant flows through the coolant outlet elbow
(thermostat housing) to the radiator (8005).
The water thermostat used in production is a high
temperature water thermostat for use with a mixture
III· IIIII~ ~ of water and permanent-type antifreeze. A low
~
temperature water thermostat should be installed if a
6 REAR 3 non-permanent type antifreeze and water coolant
5 4 solution is used.
Engine Oil Cooler

r An oil cooler (6A642) is used on the 5.8l lightning,
7.5l gasoline engine, and 7.3l Diesel Engine.
On the 5.8l lightning and 7.5l engine, the oil cooler is
part of the oil filter adapter. The lower radiator hose
(8286) attaches to the inlet side of the oil cooler and
the oil cooler outlet hose connects to the inlet side of
the water pump (8501). Oil going to the full-flow oil
filter (6731) as well.
The oil cooler used on the 7.3l Diesel engine is
attached to the side of the cylinder block (6010).
Coolant flows through a set of tubes attached to
bulkheads. As oil flows around these tubes, excess
FRONT heat is transferred to the coolant.
Q1517·H Refer to the appropriate Section 03-01 C or 03-01 D for
oil cooler maintenance information.
Typical Downflow Radiator
Part
Engine Block Heater
1 - Lifting Eyes (Part of 8005)
2 - Inlet (Part of 8005) A block heater (6A051) is standard on the 7.3l·Diesel
3 8115 Draincock and optional on other engines. When equipped, the
7.5l engine has dual block heaters - one on each
4 - Transmission Oil Cooler
side.
Fitting (Part of 8005)
5 - Transmission Oil Cooler The block heater consists of an electrical heating
Fitting (Part of 8005) element installed in one of the core plug openings in the
6 - Outlet (Part of 8005) engine block and an electrical cable which plugs into a
7 - Filler Neck (Part of 8005) standard 110 volt AC electrical outlet. It is designed to
8 - Side Bracket (Part of 8005) keep the engine coolant warm during cold weather as
9 - Side Bracket (Part of 8005) an aid in cold starting.
Cooling Fan and Clutch

Engine cooling fans are of pressed-steel construction
with the fan blades riveted to the fan center.
ALL RIGHTS RESERVED
Electrical Schematics
F-SERIES
Coolant Temperature Gauge AND
BRONCO
see EVTM for more
HOT IN START OR RUN details of this circuit
INSTRUMENT CLUSTER
(PLUG· 2)
K2027o-B
Pin
Number Circuit Circuit Function
1 570 Dedicated Ground - Closed Loop
(BK/W)
2 658 PCM to Check Engine Indicator
(PK/LG) Lamp
3 603 (DG) Failure Warning Light
K18714·C 4 977 (P/W) Dual Brake Warning Switch to
Indicator Lamp
5 343 Warning Lamp to Anti-Theft
(BB/LG) Controller Module
6 29 (Y IW) Fuel Gauge to Fuel Gauge Sender
7 3 (LG/W) Front Turn Signal Lamp (LH)
8 31 (W IR) Oil Pressure Indicator to Oil
Pressure Sending Unit
9 570 Dedicated Ground - Closed Loop
(BK/W)
10 39 (R/W) Temperature Gauge to
Temperature Sending Unit
11 - Not Used
12 608 Lamp Driver
(BK/Y)
13 640 (R/Y) Warning Lamps Feed
14 - Not Used

1. Verify the vehicle owner's original concern by
operating the engine cooling system to duplicate
the concern.

ALL RIGHTS RESERVED
2. Inspect to determine if one of the following 3. If the concern(s) remains after the inspection,
mechanical concerns apply: determine the symptom(s) and proceed to the
following Symptom Chart.
Mechanical
• Damaged hoses
• Loose / damaged hose clamps
• Damaged water thermostat
• Damaged head gaskets
• Damaged intake manifold gasket
• Damaged water pump
• Damaged radiator
• Damaged radiator coolant recovery reservoir
• Damaged heater core
Symptom Chart
ENGINE COOLING
• Loss of Engine Coolant • Damaged radiator. • GO to Pinpoint Test A.
• Damaged water pump.
• Loose I damaged radiator hoses.
• Loose I damaged heater water
hoses.
••
Damaged heater core.
Damaged engine gaskets.
• Damaged radiator coolant
recovery reservoir.
• •• •
Engine Overheats Damaged water thermostat. GO to Pinpoint Test B.
Damaged water pump.
•• Internal engine coolant leak.
Cooling fan inoperative.
•• Plugged radiator.
Plugged heater core.
•
••• •
Engine Does Not Reach Normal Damaged water thermostat. GO to Pinpoint Test C.
Operating Temperature Cooling fan.
Low engine coolant.
• Block Heater Fails to Warm Engine

Coolant
•• Block heater wiring.
Block heater.
• GO to Pinpoint Test D.
Pinpoint Tests
PINPOINT TEST A : LOSS OF COOLANT
TEST STEP RE~ULT ~ ACTION TO TAKE
A1 I CHECK COOLANT LEVEL
NOTE: If engine is hot, allow engine to cool down before Yes ~ GOtoA2.
proceeding. No ~ REFILL as outlined. GO to
• reservoir.
Check coolant level at radiator coolant recovery A7.
• Is coolant level OK?

A2 I CHECK FOR VISIBLE LEAKAGE
• the
Engine coolant has an added dye color, that makes
coolant an excellent leak detector.
Yes ~ SERVICE as outlined.
RETEST system.
• IsCheck entire cooling system for visible leakage. No ~ GOA3.
• there visible leakage?
ALL RIGHTS RESERVED
PINPOINT TEST A : LOSS OF COOLANT (Continued)

TEST STEP RESULT ~ ACTION TO TAKE
A3 I CHECK RADIATOR CAP
• Using Rotunda Radiator / Heater Core Pressure
Tester 021-00012 or equivalent, test pressure relief
Yes
No
~ GOtoA4.
~ REPLACE damaged
radiator cap as outlined in Component Testing. pressure relief cap.
• Old pressure relief radiator cap test OK? RETEST system.
A4 I CHECK COOLANT FOR INTERNAL LEAKAGE
• Visually inspect coolant in radiator coolant recovery
reservoir for signs of transmission or engine oil.
Yes ~ If engine oil is evident on
vehicles with an engine
• Is 011 evident In coolant? oil cooler, REMOVE
engine oil cooler and
INSPECT for damage.
REPLACE if damaged.
~ If engine oil is evident on
vehicles without engine
oil cooler or if oil cooler
checks out OK, REMOVE
cylinder head as outlined
in Section 03-01A,
03-01 B, 03-01 C, or
03-010, depending on
engine, and INSPECT for
leaking head gasket and
head or block cracks.
~ If transmission oil is
evident, replace
transmission oil cooler in
radiator as outlined in this
section and check
condition of transmission
oil as outlined in this
section.
No ~ GO to AS.
AS I CHECK ENGINE AND TRANSMISSION FOR COOLANT
• Remove oil level indicator for engine and
transmission.
Yes ~ If cooJant is in engine oil
on vehicles with an
• Carefully inspect oil level indicator for evidence of
coolant.
engine oil cooler,
REMOVE engine oil
• Is coolant evident? cooler and INSPECT for
damage. REPLACE if
damaged.
~ If coolant is evident in
engine oil on vehicles
without oil cooler or if oil
cooler checks out OK,
REMOVE cylinder head
as outlined in Section
03-01A, 03-01B, 03-01C,
or 03-010, depending on
engine, and INSPECT for
leaking head gasket and
head or block cracks.
~ If coolant is evident in
transmission oil, REFER
to transmission oil
coolant check in Section
07-01A, 07-01B or
07-01C.
No ~ GOtoA6.

ALL RIGHTS RESERVED
PINPOINT TEST A : LOSS OF COOLANT (Continued)

A6 I PRESSURE TEST COOLING SYSTEM
• Using Rotunda Radiator I Heater Core Pressure
Tester 021-00012 or equivalent, pressurize cooling
Yes ~ SERVICE as outlined in
this section. RETEST
system as outlined in Service Procedures in this system.
section. No ~ Cooling system is
NOTE: Check inside vehicle for possible heater operational at this time.
core leakage. RETEST system.
• Is there leakage?
A7 I CHECK COOLANT RECOVERY
• radiator
Allow engine to cool. Remove radiator cap, inspect
cap for foreign material between sealing
Yes ~ GO to AS.
No ~ REFER to Cleaning and
gasket and diaphragm. Inspection. SERVICE as
• IscapOK? outlined.
AS I CHECK RADIATOR OVERFLOW HOSE
•• Inspect
Remove radiator overflow hose.
radiator overflow hose for obstruction,
Yes ~ GOtoA9.
No ~ SERVICE hose as
cracks or cuts. required.
• Is radiator overflow hose condition OK?
A9 I CHECK RESERVOIR
•• Inspect
Replenish coolant as outlined to "Cold" level.
radiator coolant recovery reservoir for
Yes ~ REPLACE coolant
recovery reservoir.
leaks. RESTORE vehicle.
• reservoir?
Is there leakage at radiator coolant recovery No ~ REFER to
Radiator I Heater Core
Pressure Test. SERVICE
as required.
PINPOINT TEST B: ENGINE OVERHEATS

B1 I CHECK COOLANT LEVEL
NOTE: If engine is hot, allow engine to cool down before Yes ~ GOtoB2.
proceeding. No ~ REFILL as outlined. GO to
• Remove radiator cap and check coolant level at
radiator coolant recovery reservoir.
Pinpoint Test A.
• Is coolant level OK?

B2 I CHECK COOLANT CONDITION
• Check coolant for contaminants such as rust or
corrosion. Also, check for color discoloration.
Yes ~ GOtoB3.
~ FLUSH system as
No
• Is coolant condition OK? outlined in this section.
RETEST system.
B3 I CHECK FOR AIRFLOW OBSTRUCTION
• Visually inspect A I C condenser core and radiator
for obstructions, such as leaves or bugs.
Yes ~ REMOVE obstruction and
CLEAN A/C condenser
• Is there any obstruction? core and radiator as
outlined. RETEST
system.
No ~ GOto B4.
B4 I CHECK HEATER CORE OPERATION
• Install radiator cap. Yes ~ GOtoBS.
••
Start engine and allow to run. No ~ TURN engine off before it
As engine starts to warm up feel the inlet and outlet overheats. REFER to
heater water hoses. They should feel the same after Pinpoint Tests in Section
three or four minutes. 12-00. RETEST system.
• Is outlet heater water hose the same temperature
as the Inlet heater water hose?
ALL RIGHTS RESERVED
PINPOINT TEST B: ENGINE OVERHEATS (Continued)

B5 , CHECK WATER THERMOSTAT OPERATION
•• Allow engine to run for 10 minutes.

Feel the inlet and outlet heater water hose and the
Ves ~ REPLACE water
thermostat as outlined in
underside of the upper radiator hose. this section. RETEST
• Are the upper radiator hose and heater water
hoses cold? No
system.
~ LEAVE engine RUNNING.
GOto B6.
B6 I CHECK COOLING FAN
• Check for proper cooling fan clutch operation as
outlined under Component Tests.
Ves ~ GO to Section 03-00 for
procedure.
• Old cooling fan clutch operate OK? No ~ REPLACE fan clutch as
outlined in this section.
RETEST system.
PINPOINT TEST C: ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE

C1 I CHECK FOR FROZEN FAN CLUTCH
••
With engine cold, rotate fan by hand. Ves ~ GOtoC2.
Does fan rotate with slight drag from viscous No ~ REPLACE fan clutch as
fluid In fan clutch? outlined in this section.
C2 I CHECK THERMOSTAT OPERATION
• Remove water thermostat and check opening
temperature as outlined in this section.
Ves ~ REINSTALL water
thermostat and CHECK
• Does water thermostat begin to open and
become fully open at temperatures In the
temperature gauge
operation as outlined in
specifications at the end of this section? Section 13-01A or
13-018.
No ~ ·REPLACE thermostat.
PINPOINT TEST 0: ENGINE BLOCK HEATER DOES NOT OPERATE PROPERLY

01 I CHECK PLUG AND WIRE
• Check for corroded or broken spades on plug. Ves ~ GOtoD2.
• Check for broken, cracked, or cut wires. No ~ Make necessary repairs.
• Are plug and wires OK?
GO to 02.
02 I CHECK CONTINUITV OF PLUG AND WIRES
• Disconnect plugs and block heater. Check
continuity of wires from plug to element connectors.
Ves ~ GOtoD3.
No ~ REPAIR or REPLACE
• Are plug and wires OK?
plugs and wires as
necessary. GO to 04.
03 I CHECK RESISTANCE OF BLOCK HEATER
• equivalent
Use Rotunda Digital Multimeter 105-00051 or
and check for continuity across block
Ves ~ GOtoD4.
No ~ REPLACE engine block
heater pins with wires still disconnected.
heater. GO to D4.
04
• Is there continuity?
I CHECK OPERATION
•• Turn
Reconnect block heater.
ignition to O,N. Make sure engine is cold
Ves ~ ADVISE customer of
removal operation.
(ambient temperature). Shut ignition off.
No ~ GOto 05.
• Plug in block heater to known good 120V A / C
source and wait 10 minutes.
• Turn ignition to ON. Coolant should be up to 5 to
10°C (40-50°F), bottom of Normal range on gauge.
• Has system performed as specified?
ALL RIGHTS RESERVED
PINPOINT TEST D: ENGINE BLOCK HEATER DOES NOT OPERATE PROPERLY (Continued)
D5 I CHECK WARNING
• Check if block heater is warm . Yes ~ CHECK operation of
• Is block heater warm? vehicle instrument cluster
temperature gauge.
REFER to Section 13-01A
or 13-018.
No ~ GO to D1.
Component Tests 7. Install the adapter fitting from Rotunda Cooling

System Pressurization Kit 021-00012 or
Pressure Test equivalent (male thread on one end, and a hose
1. WARNING: NEVER REMOVE THE RADIATOR connector on the other end to accommodate the
CAP (8100) OR DEGAS BOTTLE CAP UNDER tester hose) tightly into the intake manifold
ANY CONDITIONS WHILE THE ENGINE (6007) (9424) or cylinder head (6049) in place of the
IS OPERATING. FAILURE TO FOLLOW THESE sending unit. -
INSTRUCTIONS COULD RESULT IN DAMAGE 8. On Bronco, F-150-250-350 and F-Super Duty
TO THE COOLING SYSTEM OR ENGINE OR series vehicles, remove the radiator overflow
PERSONAL INJURY. TO AVOID HAVING hose (8075) from the overflow nipple. Install a
SCALDING HOT COOLANT OR STEAM BLOW separate radiator overflow hose firmly on the
OUT OF THE RADIATOR (8005), USE overflow nipple. Insert the free end of separate
EXTREME CARE WHEN REMOVING THE radiator overflow hose into container of water.
RADIATOR CAP OR DEGAS BOTTLE CAP
FROM A HOT RADIATOR. WAIT UNTIL THE 9. Attach the pressure p~mp and gauge to the
ENGINE HAS COOLED, THEN WRAP A THICK adapter-fitting and pressurize the cooling system
CLOTH AROUND THE RADIATOR CAP OR to 69 kPa (10 psi).
DEGAS BOTTLE CAP AND TURN IT SLOWLY No bubbles should appear in the water container
TO THE FIRST STOP. STEP BACK WHILE THE when the system is pressurized to the LOWER
PRESSURE IS RELEASED FROM THE LIMIT (69 kPa [10 psi]). If the system is
COOLING SYSTEM. WHEN YOU ARE SURE satisfactory at the lower limit, gradually increase
ALL THE PRESSURE HAS BEEN RELEASED, the system pressure until a slight stream of
PRESS DOWN ON THE RADIATOR CAP OR bubbles appears in the water container. This is
DEGAS BOTTLE CAP (STILL WITH A the release pressure of the pressure cap.
CLOTH), TURN AND REMOVE IT.
Replace any radiator cap or degas bottle cap
Shut the engine off. which has a release pressure that is greater than
2. Open hood and install protective fender covers. the specified UPPER LIMIT pressure (90 kPa [ 13
psi]) without discharging bubbles.
3. When engine is cool, cautiously remove radiator
cap or degas bottle cap. 10. If the radiator cap or degas bottle cap does not
hold pressure, remove and wash the radiator cap
4. Disconnect battery. or degas bottle cap in clean water to dislodge all
5. Adjust the radiator coolant level (fill or drain) to foreign part_icles from the gaskets. Check the
25mm (one inch) below the filler neck opening sealing surface in the radiator filler neck.
before testing. Wipe clean, and then wet the Inspect the cam lock flanges on both sides of the
rubber sealing surfaces in the cap and filler neck filler neck for maximum cap engagement.
before installing the radiator cap tightly on the .
radiator. i
11. Pressurize the cooling system as described in
Step 6 (using a radiator cap and degas bottle cap
6. Disconnect the electrical connector from the that operate within the specified upper and lower
coolant temperature sending unit and remove the pressure limits) and observe the gauge reading
temperature sending unit from the engine. for approximately two minutes. Pressure should
With the radiator cap installed and the cooling be held between 69 and 90 kPa (10 and 13 psi)
system pressure relieved, only a small amount of and should not drop during this time.
coolant will be lost when the sending unit is
removed.
ALL RIGHTS RESERVED
12. If the pressure drops, check for leaks at the

engine-to-heater core hoses, engine-to-radiator Part
hoses, bypass hose, water valve hose (if Item Number Description
applicable), thermostat housing gasket, radiator 6 - Pressure Test Pump
and heater core (18476). Also refer to engine 021-00012 or Equivalent
system checks if a leak cannot be located in the (Part of 107-01301)
cooling system. Any leaks which are found must 7 - Pressure Relief Screw
be corrected and the system checked again. (Part of 107-01301)
If the system holds pressure proceed to next 8 - Radiator Cap Pressure Test
Adapter (Part of 107-01301)
step.
13. Release the system pressure by loosening the Radiator Cap Pressure Test
radiator cap and removing the adapter. Install the
water temperature indicator sender unit (10884), 1. Remove the radiator cap from the radiator filler
check coolant level and replenish, if necessary, neck.
with the correct coolant solution. 2. Use water to clean the radiator cap in the area of
14. NOTE: When the battery has been disconnected the rubber seal and the vacuum relief valve as
and reconnected, some abnormal drive described in this section. Immerse the radiator
symptoms may occur while the powertrain cap in water to wet the seals and install on the
cohtrol module (PCM)( 12A650) relearns its shallow filler neck of Rotunda Radiator Cap
adaptive strategy. The vehicle may need to be Pressure Test Adapter 021-00012 or equivalent.
driven 10 miles or more to relearn the strategy. (The adapter is designed to accept both deep
and shallow neck radiator caps.)
Connect battery ground cable. 3. Before installing the radiator cap on the adapter,
immerse the filler neck seal in water and install it
in the filler neck adapter. If the adapter is made of
plastic, check its sealing surfaces to be certain
that they are free of rough spots and contain no
parting lines or core marks.
The filler neck seal is reversible so that it may be
used on either a deep or shallow radiator filler
neck. It will also fit either end of the radiator cap
pressure test adapter.
4. Install the filler neck adapter with filler neck seal
on the deep filler neck end to the radiator cap
pressure test adapter.
5. Connect the female quick disconnect fitting of the
pressure test pump to the male quick disconnect
fitting of the filler neck adapter.
6. SLOWLY depress the plunger of the pressure
test pump until the pressure gauge reading stops
increasing and note the highest pressure reading
obtained. If the plunger of the pump is depressed
too fast, an erroneous pressure reading will
result.
7. Release the pressure by depressing the pressure
relief valve stem. Then, tighten the pressure relief
Part screw and repeat Step 6 (at least twice) to make
Item Number Description sure the pressure test reading is repeatable
within the acceptable gauge reading limits of the
1 8100 Radiator Cap
radiator cap and is not erratic. Refer to
2 - Filler Neck Seal Specifications at end of this section.
(Part of 107-01301)
3 - Filler Neck Adapter 8. If the pressure test gauge readings are not within
(Part of 107-01301) the acceptable gauge reading limits, replace the
4 - Quick Disconnect Fittings radiator cap, and perform a Cooling System
(Part of 107-01301) Pressure Test. If the pressure test gauge
5 - Temperature Sender readings are within the acceptable gauge reading
Pressure Hose Adapter limits, perform the Cooling System Pressure Test.
(Part of 107-01301)
(Continued)
ALL RIGHTS RESERVED
Thermostat, Water 5. Start the engine and run it at approximately 1500

NOTE: The following test can be preformed at 54°C rpm until engine temperature has normalized.
(129 ° F) for regulator thermostats and at 167 0 C 6. Adjust the engine to the testing speed in the
(333 0 F) for high temperature thermostats. Specifications at the end of this section.
If the problem being investigated is insufficient heat, 7. Operate the strobe light at water pump test
inspect the water thermostat (8575) for leakage. Hold speed and aim it at the water pump pulley. Adjust
the water thermostat up to a lighted background. Light the engine speed until the light flashes and the
leakage around the water thermostat valve (water water pump pulley marks are synchronized.
thermostat at room temperature) is unacceptable and 8. Aim the timing light at the fan retaining bolts.
the water thermostat should be replaced. A slight Adjust the strobe light until it is synchronized with
leakage of light at one or two locations on the the marked fan retaining bolt (fan appears to
perimeter of the valve of some water thermostats may stand still).
be detected. This is considered normal.
9. The fan speed must not be greater than the
Radiator Leak Test, Removed from Vehicle specified fan test speed at water pump test
CAUTION: Do not leak test an aluminum radiator speed.
in the same water that is used to leak test 10. Turn the engine OFF.
copper /brass radiators. Flux and caustic
cleaners may be present In the tank and they will 11. If the fan speed was greater than the specified
attack aluminum. fan test speed, check for proper parts usage.
Clean the radiator before leak testing to prevent If the correct parts are used, replace the fan
contaminating the test tank. Leak test the radiator in clutch (8A616).
clean water at 145 kPa (21 psi) air pressure. If the partes) are not the correct ones, replace the
A separate, clean test tank is recommended for partes) and perform the test again.
aluminum radiators. If a separate tank is not available 12. If the engaged fan clutch requirement test is going
for aluminum radiator testing, thoroughly clean the test to be performed, do not remove the tachometer,
tank each time before testing an aluminum radiator. strobe light or throttle adjusting tool.
When a plastic tank is removed to service a 13. If a Engaged Speed Fan Clutch Requirement test
tube-to-header leak, the core can be tested by is not going to be performed, remove the
clamping the tank to the core. tachometer, strobe light and throttle adjusting
tool.
Maximum Speed Fan Clutch Requirement Test
Fan Clutch Test 1. WARNING: TO AVOID THE POSSIBILITY OF
PERSONAL INJURY OR DAMAGE TO THE
Spin the fan. A light resistance should be felt. If there is VEHICLE, DO NOT OPERATE THE ENGINE
no resistance or very high resistance, the minimum WITH THE HOOD OPEN UNTIL THE FAN HAS
and maximum fan speeds must be checked as follows: BEEN FIRST EXAMINED FOR POSSIBLE
Refer to Fan Clutch Specifications at the end of this CRACKS AND SEPARATION.
section. If the disengaged fan clutch requirement test was
Disengaged Fan Clutch Requirement Test - not performed, follow Steps 1 through 5 under
Cold Disengaged Fan Clutch Requirement test.
1. WARNING: TO AVOID THE POSSIBILITY OF 2. Block off areas on each side of the radiator in the
PERSONAL INJURY OR DAMAGE TO THE engine compartment and the front of the radiator
VEHICLE, DO NOT OPERATE THE ENGINE grille (8200), this will raise the temperature of the
(6007) UNTIL THE FAN HAS BEEN FIRST air striking the fan clutch and should cause the fan
EXAMINED FOR POSSIBLE CRACKS AND blade to operate at maximum speed.
SEPARATION. 3. Place the air conditioning selector, if so equipped,
Using a suitable marker, mark the water pump in the maximum position and the blower switch in
pulley (8509), one of the fan blade retaining bolts the high position.
and the crankshaft pulley (6312). 4. Adjust the strobe light to water pump test speed.
2. Connect a tachometer to the engine. 5. Start the engine and adjust it until the water pump
3. Install a throttle adjusting tool. pulley is synchronized with the strobe light. This
will be near the engine testing speed given in
4. Connect a Sun Strobe Light or equivalent. This Specifications.
can be an SLT-1 or SLT-2 Strobotach or an STA-1
Strobe Trigger adapter for the Sun Distributor 6. Synchronize the timing light with the fan to fan
Test Stand. A Rotunda Digital Photoelectric clutch retaining bolt.
Tachometer 055-00108 or equivalent may also 7. The fan speed must meet or exceed the specified
be used for this test. minimum fan blade test speed at water pump test
speed.

ALL RIGHTS RESERVED
03·03·15 Engine Cooling 03-03-15
8. If the fan speed was less than the specified fan

test speed, replace the fan clutch.
Thermostat, Water
4.9L (300 CID) 1-6
Do not attempt to service the water thermostat
(8575). It should be replaced if it is not operating
properly.
Check the water thermostat before installing it, as
described under Component Tests in this section.
Removal
1. Drain the radiator (8005) so that the coolant level
is below the water thermostat.
r
BOLT
376255
17-24 N·m
2. Remove the coolant outlet elbow attaching bolts. (12-18 LB-FT)
WATER OUTLET
3. Pull the elbow away from the cylinder head CONNECTION
(6049) sufficiently to provide access to the water 8592 Q1521-c
thermostat.
4. Remove the water thermostat and gasket.
v-a, Gasoline
Removal
Installation
1. Drain the radiator so that the coolant level is
1. Clean the coolant outlet elbow and cylinder head
below the water thermostat.
gasket surfaces.
2. Disconnect the bypass hoses at the water pump
2. Coat a new gasket with Perfect Seal Sealing
(8501) and intake manifold (9424).
Compound B5A-19554-A or 07AZ-19554-BA
(ESR-M 18P2-A and ESE-M4G 115-A) or 3. Remove the bypass tube.
equivalent. 4. Remove the water outlet housing attaching bolts.
3. Position the gasket on the cylinder head opening. 5. Bend the upper radiator hose (8260) upward and
The gasket must be positioned on the cylinder remove the water thermostat and water hose
head before the thermostat is installed. connection gasket (8255).
4. The coolant outlet elbow contains a locking
Installation
recess into which the water thermostat is turned
and locked. Install the water thermostat with 1. Clean the water outlet housing gasket surfaces.
pellet side out. Coat a new water hose connection gasket with
Perfect Seal Sealing Compound B5A-19554-A or
5. Turn the water thermostat clockwise to lock it in
07AZ-19554-BA (ESR-M 18P2-A or
position on the flats cast into the outlet elbow.
ESE-M4G 115-A) or equivalent.
6. Position the coolant outlet elbow against the
2. Position the water hose connection gasket on the
cylinder head. Install and tighten the attaching
intake manifold or cylinder head opening.
bolts to 16-24N·m (12-18 Ib-ft).
3. Install the water thermostat in the intake manifold
7. Fill and bleed the cooling system as described in
opening with the copper pellet or element toward
this section.
the engine (6007) and the thermostat flange
8. WARNING: DO NOT STAND IN LINE WITH OR positioned in the recess. If the water thermostat
NEAR RADIATOR FAN BLADE (8600) WHEN is improperly installed, it will cause a retarded
ENGINE IS RUNNING. flow of coolant.
Check for leaks and proper coolant level after the 4. Position the water outlet housing against the
engine has reached normal operating intake manifold.
temperatures.
5. Install and tighten the attaching bolts. Refer to
Specifications.
6. Install the water bypass line and tighten hose
connections.
7. Fill and bleed the cooling system as described in
this section.

ALL RIGHTS RESERVED
8. WARNING: DO NOT STAND IN LINE WITH OR

NEAR RADIATOR FAN BLADE WHEN ENGINE
IS RUNNING.
Operate the engine until normal operating WATER
temperature is reached; then check the coolant OUTLET
level and check for leaks. 8592
Thermostat Installation, 5.0L/5.8L Shown WATER OUTLET

I
lJ4oa--- CONNECTION
GASKET
~ 8255
I~THERMOSTAT
8575
WATER
PUMP
8501
Q4241-A
Installation
1. Install the water thermostat and the thermostat
housing a-ring in the water hose connection.
2. Install the water hose connection and install
thermostat housing retaining screws. Tighten
screws to 20 N·m (15Ib-ft).
3. Connect the upper radiator hose to the water
hose connection and install hose clamp at the
Part water hose connection.
Item Number Description 4. Install the drive belt at the drive belt tensioner
1 8255 Water Outlet Connection pulley.
Gasket 5. Refill and bleed the engine cooling system as
2 8592 Water Outlet Connection described in this section.
3 391428 Screw, 5/ 16-18 x 1.25
4 8575 Thermostat
5 391430 Screw 5/ 16-18 x 1.75
A - Insert ,with Copper Pellet Water Pump
Towards Engine
Refer to the appropriate engine Section 03-01 for
B - Tighten in Sequence
Water Pump Removal and Installation.
Indicated in Text to
17-24 N·m (12-18 Lb-Ft)
Diesel
Constant Tension Hose Clamp
Removal
1. Drain the cooling system. Removal
2. Disconnect the drive belt (8620) at the drive belt 1. Pressure test the system to determine the
tensioner pulley (68217). location of the leak. Only if it is a radiator hose
joint that is leaking then proceed with the
3. Remove the upper radiator coolant hose clamp at following steps.
the water hose connection (8592) and
disconnect the upper radiator hose from the 2. Reseat the clamp by using a pair of pliers or vice
water hose connection. grips to squeeze the clamp tangs together
(loosen the clamp), reseat the hose, then
4. Remove retaining screws and the water hose re-release the clamp. Pay close attention that the
connection. clamp is straight (perdenticular to the hose) and
5. Remove the thermostat housing a-ring and water is not cocked over the bead.
thermostat.

ALL RIGHTS RESERVED
3. Pressure test the system again. If the leak Installation

persists, check the radiator hose, clamp, and CAUTION: Ensure the hose clamps are beyond
connector (see step 5) for damage. If damage is the bead and placed in the center of the clamping
observed, replace the damaged part. surface of the connections.
Position the hose clamps at least 3.2mm (1 /8 inch)
Diameter of Connector Clamp Part Number from each end of the hose. Coat the connection areas
1-1/2Inch N808275-8101 with an approved water-resistant sealer and slide the
1-3/4Inch N808276-8 101
hose on the connections. Tighten hose clamps.
2 Inch N808732-8100 Fill the radiator with the recommended permanent
antifreeze solution and supplemental coolant additive.
4. If clamp is only to be removed, residual glue may Operate the engine (6007) for several minutes, then
exist on the hose. If necessary, remove the glued check the hoses and connections for leaks. Retighten
clamp by applying a heat gun at 420 degrees hose clamp.
Fahrenheit to the glued portion for approximately
1 minute. The glue is suppose to dissipate with
the thermal engine cycle, so it may not be a
factor. The glue is located 180 degrees away Bypass Hose
from the tangs.
5.0L and 5.8L
5. Inspect the connector for any scratches or
foreign materials on the sealing surface. If Removal
connector is damaged, replace. 1. Open hood (16612) and remove air cleaner outlet
Installation tubes (98659).
1. Push the hose onto the connector until it is 2. Drain cooling system as outlined in this section.
completely seated against the hose stop. If 3. Loosen A / C hose clamps (198679).
lubricant is to be used to assist hose installation,
use premixed Merpol (ESE-M998 144-8) or 4. WARNING: IF WATER BYPASS TUBE OR
water. Any other type of lubricant could HOSE (8548) HAS BEEN ON VEHICLE A
potentially cause the joint to leak. LENGTH OF TIME, TWIST TO BREAK LOOSE
BEFORE PULLING OFF. WATER BYPASS
2. Release the clamp by carefully removing the TUBE OR HOSE MAY SUDDENLY BREAK
retaining clip using pliers or vice grips. During FREE, CAUSING HAND TO BE INJURED BY
removal, the clip should be held securely at all HITTING SHARP OBJECTS.
times. Do not pryor pop the clip off the clamp.
Twist water bypass tube or hose to break loose
3. Check that the clamp is straight, fully released seal and remove.
and seated on the sealing area of the hose and
connector. The clamp should NOT be partially or Installation
completely cocked over or on top of the bead at 1. Install A / C hose clamps loosely on water bypass
the end of connector. tube or hose.
2. Put hose onto manifold and water pump nipples.
3. Slide A / C hose clamps into place and tighten to
Radiator Hoses 3..4 N·m (27-35Ib-in).
4. Refill cooling system as outlined in this section.
Upper and Lower
5. Install air cleaner outlet tubes.
Removal
6. Start engine (6007) and check for leaks.
Radiator hoses should be checked as directed in the Retighten hose clamps (8287) after engine has
applicable Maintenance Schedule. Refer to Section warmed up.
00-03. Replace whenever hoses become cracked,
rotted or have a tendency to collapse.
Drain the radiator (8005) and slide the hose clamps
(8287) onto hose at each end of the hose to be
removed. Slide the hose off the radiator connection
and the water outlet connection (upper radiator hose
(8260» or the water pump connection (lower radiator
hose).
1995 F-150, F-250, F-350, Bronco, F-8uper Duty Powertrain, Drivetrain July 1994
ALL RIGHTS RESERVED
Bypass Hose, 5.8L, Typical of 5.0L
..
FRONT OF ENGINE
•
FRONT OF ENGINE
VlEWC
Part Part
1 383522-8 Clamp B - Center Line Parallel to Intake
2 8597 Bypass Hose Manifold Deck
3 389772-8 Clamp C - Center Line Parallel to Front
Face of Cylinder Block
4 8501 Water Pump Assembly
(Upper Nipple) D - Align 10°-30°
5 8592 Water Hose Connection E - 1.5mm (0.06 Inch) Gap
Typical
A - Tighten to 1.6-2.2 N·m
(15-20 Lb-In) F - 3.0mm (0. 12 Inch) Maximum
(Continued)
7.5L Installation
Removal 1. Position A I C hose clamps on nipples.
1. Open hood and drain cooling system as outlined 2. CAUTION: Do not kink hose. This breaks
in this section. cords and may cause a permanent kink
which could cause a coolant restriction.
2. Remove air cleaner outlet tubes.
Bend water bypass tube or hose and work onto
3. Remove distributor (12127) as outlined in Section nipples. Do not bend water bypass tube or hose
03-07. too tight so it kinks.
4. Loosen A/C hose clamps. 3. Position A/C hose clamps and tighten to 1.3-2.2
5. Using sharp knife, cut old water bypass tube or N·m (12-20 Ib-in).
hose in two in the middle. 4. Refill cooling system as outlined in this section.
6. Remove the two halves of the water bypass tube 5. Install and time distributor as outlined in Section
or hose. It may be necessary to pry against the 03-07A.
intake manifold (9424) or water pump (8501)
with a medium-bladed screwdriver to break loose 6. Start engine and check for leaks. Retighten hose
water bypass tube or hose from nipple. clamps when engine has warmed up.
7. Install air cleaner outlet tubes.

ALL RIGHTS RESERVED
Bypass Hose, 7.5L
VIEWS
VIEWS A
ANDB
Q4696-A
Part Part
1 8287 Hose Clamp A - Tighten to 1.3-2.2 N·m
2 8597 Bypass Hose (12-20 Lb-In)
3 8501 Water Pump B - Center Line Parallel to
Vertical Center Line of
4 9424 Lower Intake Manifold Engine
5 - Nipple (Part of 9424) C - 80°-100°
(Continued)
Water Inlet Radiator

Tube - 7.3L Diesel Only Aluminum Core, Crossflow, F-150, F-250,
Removal and Installation F-350 Super Duty Chassis Cab and Motorhome
Chassis with Gasoline Engine
1. Drain the cooling system.
Removal
2. Raise vehicle.
1. Drain the cooling system by removing the
3. Remove the lower radiator hose clamp and radiator cap (8100) and opening the radiator
disconnect the lower radiator hose (8286) from draincock (8115) located at the lower rear corner
the water pump inlet. of the radiator tank. To prevent coolant loss when
4. Remove the water pump inlet retaining bolts. draining radiator (8005), slip a hose on the
5. Remove the water pump inlet and O-ring. radiator draincock and drain coolant into a clean
container.
6. To install, reverse removal procedure.
2. Remove the rubber radiator overflow hose
(8075) from the radiator coolant recovery
reservoir (8A080) and detach it from the radiator.
3. Remove the two upper attaching screws, lift the
fan shroud (8146) out of the lower retainer clips
and drape it on the fan. On F-Super Duty
Motorhome Chassis vehicles remove the two
screws at the bottom of the fan shroud.
4. Loosen the upper and lower hose clamps at the
radiator and remove the upper radiator hose
(8260) and lower radiator hose (8286) from the
radiator connectors.

ALL RIGHTS RESERVED
5. Remove the heated water bypass hose 7. Install two upper attaching bolts or screws.
(E40D-equipped vehicles only) located directly Tighten to specifications.
below the overflow nipple on the radiator outlet 8. Connect the two automatic transmission (if so .
tank. equipped) oil cooling lines to radiator connectors
6. Disconnect the two automatic transmission (if so and tighten tube nuts to 16-24 N·m (12-18 Ib-ft) or
equipped) oil cooling lines from radiator fittings. clamps to 4-5 N·m (35-44Ib-in).
7. Remove the two radiator upper attaching screws 9. Attach upper radiator hose and lower radiator
or bolts. hose to radiator. Position hose on radiator
8. Tilt the radiator back approximately 25mm (one connection so that index arrow on hose is in line
inch) and lift directly upward, clear of the radiator with mark on connection. Install double wire
support bracket (8052) and fan blade (8600). clamps and tighten to 3-4 N·m (27-35Ib-in).
9. If either upper radiator hose or lower radiator 10. Position fan shroud on the lower retainer clips and
hose is to be replaced, loosen clamp at the attach the top of the fan shroud to radiator with
engine end and slip the hose off the connection two screw and washer assemblies. On F-Super
with a twisting motion. Duty Motorhome Chassis vehicles install the two
lower screws. Tighten screws to 6-8 N·m (53-71
10. Lift the fan shroud off the fan and remove from the Ib-in).
vehicle.
11. Attach rubber radiator overflow hose from
11. Remove the radiator mounting insulators (8124). radiator coolant recovery reservoir to radiator.
Installation 12. WARNING: DO NOT STAND IN LINE WITH OR
1. Position the radiator mounting insulators to the NEAR RADIATOR FAN BLADE WHEN ENGINE
lower frame. IS RUNNING.
2. Position fan shroud on fan until radiator is NOTE: A 50/50 mixture of coolant concentrate
installed. and water is recommended to maintain best
overall performance. To avoid damaging the
3. If either upper radiator hose or lower radiator radiator or engine, the coolant concentrate
hose has been replaced, install on engine (6007) should not exceed 60 percent.
with index arrow in line with mark on fitting on
engine. Install double wire clamps and tighten to Install new 50/50 mixture of water and Premium
3-4N·m (27-35Ib-in). Cooling System Fluid E2FZ-19549-AA or
4. Install the heated water bypass hose ESE-M97844-A prus 1.4 liters (1.5 qts.) of Heavy
(E40D-equipped vehicles only) to the nipple Duty Cooling System Additive FW-15 or
located below the overflow tank. equivalent meeting Ford specification
5. Position radiator into engine compartment to ESN-M998169-A and operate the engine for 15
radiator support (16138), being careful to clear minutes. Check the coorant level and bring it up to
fan. within 38mm (1-1/2 inches) of the radiator filler
neck.
6. Inspect the radiator mounting insulators. Replace
if necessary.
RUBBER
INSULATOR
8125
STEEL
INSERT
8C298
02281-18

ALL RIGHTS RESERVED
Radiator Installation, F-150, F-250, F-350 and Bronco 4.9L (300 CID) Engine
VIEWY
4.9 LITER ENGINE

MAIN VIEW
•
FRONT OF VEHICLE ~__V.;",,;,I_EW
__ X_ _......_ _Vl_EW_Z
_ _......
Q2144-G
Part Part
1 8005 Radiator 13 17B613 Reservoir Assembly
2 N804639-S2 Nut 14 19E525 Upper Radiator Air Deflector
3 8075 Radiator Overflow Hose 15 W611631-S36 Screw
4 8146 Fan Shroud 16 88407 Lower Radiator Air Deflector
5 8286 Lower Radiator Hose A - Tighten to 3-4 N·m
6 8146 Fan Shroud (27-35 Lb-In)
7 N606677-S2 Screw B - Tighten to 5-8 N·m
(44-71 Lb-In)
8 8260 Upper Radiator Hose
9 N606691 Screw
(27 -35 Lb-In)
10 389252-S 100 Clamp
11 8124 Radiator Mounting Insulator (8-11 Lb-Ft)
12 8052 Radiator Support Bracket E - Tighten to 25-30 N·m
(Continued) (18-22 Lb-Ft)

ALL RIGHTS RESERVED
Radiator Installation, F-150, F-250, F-350 and Bronco 5.0l (302 CID) and 5.8l (351 CID) Engines
.",
FRONT OF VEHICLE
VIEWY VlEWZ
Q4075-B'
Part Part
1 17618 Windshield Washer 9 8286 Lower Radiator Hose
Reservoir (Except Lightning)
2 389252-S 100 Clamp 10 8146 Fan Shroud
3 381440-S200A Hose, Overflow 11 N807151-S2 Screw and Washer, Me x 1.0
4 N804639-S2 U-Nut, M6 x 1.0 5-7 N·m (4-5 Lb-Ft)
5 19E525 AIC Spoiler A - Line Up Paint Stripe Front
Side of Hose
6 8005 Radiator
7 8260 Upper Radiator Hose
8 - Line Up Paint Stripe with
80ss on Connector
8 8286 Lower Radiator Hose
(Lightning Only)
(Continued)
1995 F-150, F-250, F-350, Bronco, F-Super Duty P~wertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
Radiator Installation, F-250 HD, F-350 and F-Super Duty Chassis Cab with 7.5L (460 CID) Engine
~
FRONT OF VEHICLE
VIEWY VlEWZ
Q4078-B
Part Part
1 17618 Windshield Washer 9 8146 Fan Shroud
Reservoir 10 N807151-S2 Screw and Washer
2 389252-S 100 Clamp A - Tighten to 3-4 N·m
3 381440-S200A Hose (27-35 Lb-In)
4 N804639-S2 U-Nut B - Align Arrow at 12 o'Clock
5 19E525 Deflector Position
6 8005 Radiator C - Align Arrow to Boss
7 8260 Upper Radiator Hose 0 - Tighten to 5-7 N·m
(4-5 Lb-Ft)
8 8286 Lower Radiator Hose
(Continued)

ALL RIGHTS RESERVED
~ Radiator Installation, F-Super Duty Motorhome Chassis
7
VIEW X
~
6...----....•
.,
FRONT OF VEHICLE
~
FRONT OF VEHICLE
.,.
FRONT OF VEHICLE
VIEW X VlEWZ
Q1781-E
Part Part
1 8260 Upper Radiator Hose 4 8A080 Radiator Coolant Recovery
2 8124 Radiator Mounting Insulator Reservoir
3 N801731 Nut 5 8286 Lower Radiator Hose
6 8005 Radiator
(Continued)
(Continued)
1995 F·150, F·250, F·350, Bronco, F·Super Duty Powertrain, Drivetrain July 1994
ALL RIGHTS RESERVED
Part Part
7 N606691 Bolt 11 8052 Radiator Support Bracket
8 8146 Fan Shroud 12 N606064 Bolt
9 N620482 Nut 13 52721 Bolt
10 N620481 Nut 14 N605786 Bolt
(Continued)
Aluminum Core Downflow, F-Super Duty 3. Install the upper radiator hose and lower radiator
Commercial Chassis, 7.3L Diesel hose and tighten the hose clamps.
Removal 4. Install the fan shroud and tighten the eight shroud
bolts.
1. Drain the radiator by removing the radiator cap
and disconnecting the lower radiator hose. To 5. Install the radiator overflow hose to the radiator
prevent coolant loss when draining the radiator, coolant recovery reservoir.
drain the radiator into a clean container. 6. WARNING: DO NOT STAND IN LINE WITH OR
2. Remove the rubber radiator overflow hose from NEAR THE FAN BLADE WHEN THE ENGINE IS
the radiator coolant recovery reservoir. RUNNING.
3. Remove the eight attaching bolts and lift the fan NOTE: A 50/50 mixture of coolant concentrate
shroud back and drape it over the fan. and supplemental coolant additives is
recommended to maintain best overall
4. Loosen the upper radiator hose clamp and performance. To avoid damaging the radiator, the
remove the upper radiator hose from the radiator. coolant concentrate should not exceed 60
5. Remove the two radiator attaching bolts from the percent. Add coolant additive FW-15 to coolant
side mounts, and remove the radiator mounting mixture, refer to Cooling System Capacities at
insulators from the mounting pads. the end of this section.
6. Remove the upper radiator support by removing Install new 50/50 mixture of su~plemental
four attaching bolts. Remove the radiator by coolant additives and Premium Cooling System
lifting up and out. Fluid E2FZ-19549-AA or equivalent meeting Ford
7. Lift the fan shroud off the fan and remove from the
specification ESE-M97844-A plus 1.4 liters (1.5
vehicle.
qts.) of Heavy Duty Cooling System Additive
FW-15 or equivalent meeting Ford specification
Installation ESN-M998169-A and operate the engine for 15
1. Position the fan shroud on the fan. minutes. Check the coorant level and bring it up to
within 38mm (1-1/2 inches) of the radiator filler
2. Install the radiator from the bottom into the upper neck. Add two Cooling System Stop Leak Pellets
radiator insulators, then install the rubber D9AZ-19558-A or eguivalent meeting Ford
insulators and the mounting bolts. lighten the specification ESE-M99837-8.
bolts to 102-142 N·m (75-105 Ib-ft).
ALL RIGHTS RESERVED
~ Radiator Installation, 7.3L Diesel
©
I
VIEW A VIEWS VIEWe
Q4250-A
Part Part
1 N620480-S2 Nut 14 N605905-S2 Screw and Washer
2 8C062 Radiator Coolant Recovery 15 8260 Upper Radiator Hose
Reservoir Strap 16 8286 Lower Radiator Hose
3 N605689-S36 Screw and Washer 17 8146 Fan Shroud
4 8A080 Radiator Coolant Recovery 18 N606677-S2 Screw and Washer
Reservoir Assembly
5 N800854-S2 Nut 19 8005 Radiator
6 N605519-S2 Bolt 20 N605689-S36 Screw and Washer
7 8C062 Bracket Assembly
8 N800296-S 100 U-Nut A - Tighten to 9-12 N·m
9 8A348 Bracket (7-9 Lb-Ft)
10 16747 Hood Latch Support Brace B - Tighten to 24-34 N·m
(18-25 Lb-Ft)
11 8A347 Bracket
12 N620481-S2 Nut
(44-71 Lb-In)
13 N800854-S2 U-Nut D - Tighten to 7-11 N·m
(Continued) (62-97 Lb-In)
ALL RIGHTS RESERVED
Radiator Downflow, F-Super Duty Commercial 4. Loosen the upper radiator hose clamp, and
Chassis remove the upper radiator hose from the radiator.
Removal 5. Remove the two radiator attaching bolts from the
side mounts, and remove the radiator mounting
1. Drain the radiator by removing the radiator cap insulators from the mounting pads.
and disconnecting the lower radiator hose. To
prevent coolant loss when draining the radiator, 6. Remove the upper radiator support by removing
drain the radiator into a clean container. four attaching bolts, and remove the radiator by
lifting up and out.
2. Remove the rubber radiator overflow hose from
the radiator coolant recovery reservoir. 7. Lift the fan shroud off the fan and remove from the
vehicle.
3. Remove the eight attaching bolts and lift the fan
shroud back and drape it over the fan.
Radiator Installation, F-Super Duty Commercial Chassis
14
FRONT OF VEHICLE
# Q1773-E
Part Part
1 8005 Radiator 7 8260 Upper Radiator Hose
2 390235 90 0 Elbow 8 388656 Clamp
3 8146 Fan Shroud 11 88448 Pipe
4 16138 Radiator Support 12 8286 Lower Radiator Hose
5 8A354 Clamp 13 390882 Nut
6 88463 Insulator Assembly 14 8A421 Insulator
(Continued) 15 44879-S2 Washer
ALL RIGHTS RESERVED
Installation 2. Connect the radiator overflow hose to the

1. Position the fan shroud on the fan.
3. Connect the radiator overflow hose to the
2. Install the radiator from the bottom into the upper radiator filler neck nipple.
radiator insulators, then install the rubber
insulators and the mounting bolts. Tighten the 4. WARNING: DO NOT STAND IN LINE WITH OR
bolts to 102-142 N·m (75-105Ib-ft). NEAR RADIATOR FAN BLADE (8600) WHEN
3. Install the upper radiator hose and lower radiator ENGINE IS RUNNING.
hose and tighten the hose clamps. Fill and bleed the cooling system as described in
4. Install the fan shroud and tighten the eight shroud this section. Check for coolant leaks and proper
bolts. coolant level after the engine (6007) reaches
normal operating temperatures.
5. Install the radiator overflow hose to the radiator
coolant recovery reservoir.
6. WARNING: DO NOT STAND IN LINE WITH OR
NEAR THE RADIATOR FAN WHEN THE
ENGINE IS RUNNING.
NOTE: A 50/50 mixture of coolant concentrate
and water is recommended to maintain best
overall performance. To avoid damaging the
radiator, the coolant concentrate should not
exceed 60 'percent. Include the recommended
amount of supplemental coolant additives. Refer
to coolant chart under Specifications.
Install new 50/50 mixture of water and Premium
Cooling System Fluid E2FZ-19549-AA or
ESE-M97B44-A prus 1.4 liters (1.5 qts.) of Heavy
Duty Cooling System Additive FW-15 or
ESN-M99B169-A and operate the engine for 15
minutes. Check the coorant level and bring it up to
within 38mm (1-1/2 inches) of the radiator filler
neck. Add two Cooling System Stop Leak Pellets
D9AZ-19558-A or equivalent meeting Ford
specification ESE-M99B37-B. Include the
recommended amount of supplemental coolant
additives. Refer to coolant chart under
Specifications.
Q2605-D
Part
Radiator Coolant Recovery Reservoir Item Number Description
All Except 7.3L Diesel Engine 1 8005 Radiator
Removal 2 8A08D Radiator Coolant Recovery
Reservoir
1. Pinch the radiator overflow hose (B075) until it is 3 N606676-S2 Bolt
closed. Remove the radiator overflow hose from 4 8C062 Radiator Coolant Recovery
the radiator filler neck nipple. Drain the coolant Reservoir Strap
from the coolant radiator coolant recovery 5 N800854-S2 U-Nut
reservoir (BAOBO).
2. Remove the strap or bracket attaching bolt(s)
and remove the radiator coolant recovery
reservoir.
3. Disconnect the radiator overflow line at the
4. Remove the radiator overflow hose from the
Installation
1. Position the radiator coolant recovery reservoir in
the chassis and install the strap or bracket
attaching bolt(s).
ALL RIGHTS RESERVED
7.3L Diesel Engine

RADIATOR
Removal COOlANT ClAMP
RECOVERY 389252-5100
1. Pinch the radiator overflow hose until it is closed. RESERVOIR
Remove the radiator overflow hose from the 8A080
radiator filler neck nipple. Drain the coolant from
the radiator coolant recovery reservoir.
2. Remove the radiator overflow hose from the
3. Remove screws attaching radiator coolant
recovery reservoir to front fender (16005) and
remove.
Installation
1. Position the radiator coolant recovery reservoir
and install the attaching screws.
radiator filler neck nipple.
CONNECTOR
4. WARNING: DO NOT STAND IN LINE WITH OR Q4243-A
NEAR RADIATOR FAN BLADE WHEN ENGINE
IS RUNNING.
Check for coolant leaks and proper coolant level
after the engine reaches normal operating
temperatures.
ALL RIGHTS RESERVED
03-03-30 . Engine Cooling 03-03-30
Radiator Coolant Recovery. Reservoir and Surge Tank, F-Super Duty Commercial Chassis
FRONT OF
VEtlCLE
~
@®-
VIEWY
FOR CONTINUATION (
SEE MAIN VIEW ~
~ ... ,,,
~_.~
'lIP
FRONT OF
ENGINE
VIEW X
Q1774-E
ALL RIGHTS RESERVED
Part Part
1 8A080 Radiator Coolant Recovery 14 8286 Lower Radiator Hose
Reservoir 15 388656 Clamp
2 88290 Strap 16 58635 Bolt
3 388650 Clamp 17 N800878 Spacer
4 388652 Clamp 18 388650 Clamp
5 8C063 Hose 19 8A354 Anti-Squeak Pad
6 8A081 Bracket 20 8K196 Strap
7 9B873 Strap 21 8B420 Anti-Squeak Strap
8 381201 Hose 22 605773 Bolt
9 N605804-S2 Bolt 23 372751 Clip
10 8C045 Coolant Recovery Reservoir 24 N620482-S2 Nut
11 380940 Connector 25 382323 Connector
12 387926-S Elbow 26 357518 Bushing
13 8B448 Pipe A - Tighten to 11-17 N·m
Cooling Fan Blade and Fan Clutch,

Mechanical
4.9LMFI

Fan Clutch Holding Tool T84T-6312-C
Fan Clutch Nut Wrench T93T-6312-B
y'
Removal
1. Remove the fan shroud (8146). Refer to Section
03-03.
2. CAUTION: The large clutch assembly nut has
a right-hand thread and must be rotated
counterclockwise to remove it. 8CREWAND
WASHER
Remove the fan clutch (8A616) from the water ASSEMBLY
pump (8501) by turning the large nut, which is 5763-82 FAN CLUTCH
16-24 N-m 8A616
part of the fan clutch, using Fan Clutch Holding 53-71 N-m
Tool T84T-6312-C and Fan Clutch Nut Wrench (12-17 LB-FT)
(40-53 LB-FT)
T93T-6312-B. Q4697-A
3. Remove the fan blade (8600) and fan clutch. Installation
4. If the fan blade and fan clutch have to be 1. Install all of the bolts attaching the fan blade to
separated, remove the remaining bolts attaching the fan clutch. Tighten all bolts to 16-24 N·m
the fan blade to the fan clutch. ( 12-18Ib-ft).
2. CAUTION: The clutch assembly nut has a
right-hand thread and must be rotated
clockwise to tighten it.
Install the fan blade / fan clutch on the water pump
hub by turning the large nut, which is part of the
clutch, using Fan Clutch Holding Tool
T84T-6312-C and Fan Clutch Nut Wrench
T93T-6312-8.
3. Install the fan shroud as outlined in this section.
ALL RIGHTS RESERVED
5.0l, 5.al and 7.5l Engines Removal

Removal 1. Partially drain the engine cooling system.
1. Remove fan shroud and radiator (8005) if 2. Remove the upper radiator hose (8260).
necessary, as outlined is this section. 3. Disconnect the coolant reservoir hose at radiator.
2. Remove four screws retaining clutch on water 4. CAUTION: Right-hand thread. Remove by
pump hub. turning nut counterclockwise.
3. Pull fan clutch and fan blade off water pump pilot Remove the fan clutch using Fan Clutch Nut
and remove assembly from vehicle. Wrench T83T-6312-B and Fan Clutch Pulley
4. Remove four screws and separate fan clutch HoJder T94T-6312-AH, set fan clutch in fan
from fan blade. shroud.
Installation
1. Position fan blade to fan clutch and attach with
four screws. lighten screws to 16-24 N·m (12-17 FAN CLUTCH
Ib-ft). NUT WRENCH
T83T-6312-B
2. Position fan blade and fan clutch to water pump
pulley (8509) and attach with four screws.
lighten screws to 16-24 N·m (12-18 Ib-ft).
3. Install the fan shroud as outlined in this section.
A23072-A
5. Remove the radiator fan shroud screws.
Part
Item Number Description 6. Remove the radiator fan shroud, and fan clutch.
1 8509 Water Pump Pulley 7. Remove the bolts attaching the fan blade to the
2 57632-5 Screw and Washer
fan clutch.
Assembly, 5/ 16-18 x .62 Installation
Hex
3 8600 Fan Blade (5.0 and 5.8L) 1. Install the bolts attaching the fan blade to the fan
clutch. Tighten to 16-24 N·m (12-18 Ib-ft).
4 8600 Fan Blade (7.5L)
5 8A616 Fan Clutch 2. Install the radiator fan shroud, and fan clutch.
6 380288-52 Screw and Washer 3. Install the radiator fan shroud screws.
Assembly, 5/ 16-24 x .88
Hex 4. CAUTION: Right-hand thread. Install by
A - 16-24 N·m (12-18 Lb-Ft) turning nut clockwise.
Install the fan clutch using Fan Clutch Nut Wrench
7.3l Diesel T83T-6312-B and Fan Clutch Pulley Holder
T94T-6312-AH.
Fan Clutch Nut Wrench T83T-6312-B
Fan Clutch Pulley Holder T94T-6312-AH
ALL RIGHTS RESERVED
Fan Blade and Clutch Assembly, 7.3L Diesel Engine
NOTE: RIGHT HAND THREAD FAN

SCREW AND
WASHER ASSEMBLY CLUTCH
57633-8410 8A616
16-24 N-m
(141-212 LB-IN)
FAN
CLUTCH
8A616 VlEWZ
113-153 N-m
(84-112 LB-FT) Q4238-B
5. Install the coolant reservoir hose to radiator. 4. Remove the radiator tank containing the
6. Install the upper radiator hose. damaged or leaking oil cooler.
7. Refill and bleed the engine cooling system as 5. CAUTION: Care should be exercised during
described in this section. the disassembly and assembly solder
operation of radiator components. Avoid
Copper /Brass Core Radiator excess heat concentration which could
Replacement of the automatic transmission oil cooler result in burning through the radiator sheet
or radiator draincock (8115) in the radiator lower tank metal or loosening an adjoining soldered
is usually performed by radiator specialty shops. area.
However, the operation can be performed, providing Melt the puddled solder from the oil cooler inlet
proper equipment is available. and outlet fittings, or radiator draincock. Remove
The radiator draincock is soldered directly to the the retaining rings from the oil cooler fittings.
radiator lower tank. 6. Remove the oil cooler or radiator draincock.
Only manufactured or natural gas torches should be 7. Clean the soldered surface areas and inspect and
used to perform radiator repairs. Do not use tin as necessary to ensure proper solder bonding.
acetylene.
Installation
No attempt should be made to repair a fractured
radiator tank. Should a fractured tank be encountered, 1. NOTE: If one-piece radiator draincock is not
it must be replaced. Tank repairs usually result in available, a threaded boss (8120) and radiator
repeat failures, due to the flexing of the tank caused draincock must be used. Solder the boss into the
by pressure increase and decrease. tank following the procedure for one-piece
draincocks, then wrap the draincock threads with
Removal sealer tape and install the radiator draincock in
1. Drain the cooling system. To prevent coolant loss the boss. Tighten the draincock to 16-20 N·m
when draining radiator, slip a hose on the radiator ( 12-15Ib-ft).
draincock and drain coolant into a clean Radiator draincock: Position the replacement
container. radiator draincock or draincock boss in the tank
2. Remove the radiator from the vehicle as opening and solder using the procedures for oil
described in this section. cooler.
3. Thoroughly clean the radiator assembly internally Oil Cooler: Install the replacement oil cooler
and externally by submerging in a tank filled with assembly into the tank openings and secure
a caustic solution. Then, using clean water, flush cooler with new retaining rings. For bead design,
until the caustic solution is removed from all push ring past fitting bead. Retaining ring tangs
internal and external surfaces. should point away from tank.
ALL RIGHTS RESERVED
2. Puddle-solder the oil cooler fitting completely to 8. NOTE: A 50/50 mixture of coolant concentrate
the tank. and water is recommended to maintain best
3. Seat the tank assembly in the header well and overall performance. To avoid damaging the
solder securely, completely filling the well. Use engine (6007) or radiator, the coolant
40-60 solder with zinc chloride 30 (BAUME), 5-B concentrate should not exceed 60 percent.
NALCO or equivalent flux. Include the recommended amount of
supplemental coolant additives for the 7.3L
4. Flush off all excess acid, internally and externally. engine. Refer to coolant chart under
5. Pressure test the radiator assembly to 132-137 Specifications.
kPa (19-20 psi) for leaks. Flush the cooling system and refill and bleed with
6. Paint as required. the recommended mixture of all-season coolant.
Refer to Cleaning and Inspection in this section for
7. Install the radiator and fan shroud in the vehicle procedure.
as described in this section.
Typical Crossflow and Downflow Radiator Oil Coolers
COOLER ASSEMBLY
COOLER ASSEMBLY
INSTALL RETAINING RINGS

BEFORE SOLDERING 384173-S5 OR
SOLDER OIL 374551-S5
TIGHTEN TO 2-6 N·m COOLER FITTINGS (2REQ'D)
(20-50 IN-LB) COMPLETELY
(THREADED DESIGN) TO TANK (BEAD DESIGN)
Q1524·D
Radiator Draincock
Aluminum Core Radiator
Removal
1. Turn the stem of radiator draincock (8115)
counterclockwise to unscrew the stem and drain
the radiator (8005). After the radiator is drained,
and when the stem is unscrewed to the end of the
threads, pull the stem from the radiator tank and
draincock body.
ALL RIGHTS RESERVED
2. Remove the draincock body from the radiator Copper/Brass Radiator

tank by squeezing the sides together with a pair
of needle nose pliers. Then, pull the body from the Removal and Installation
inlet tank. 1. Drain the cooling system and remove the
threaded radiator draincock from the radiator as
2. Inspect the pipe threads on the radiator
draincock and the threaded radiator draincock
boss in the radiator tank.
3. If the boss threads are damaged, repair them
with a 1/4-inch pipe tap. If the threads are
damaged beyond repair, install a new radiator
draincock boss in the radiator tank.
4. Apply a small amount of Pipe Sealant with
TEFlON® D8AZ-19554-A or equivalent meeting
Ford specification WSK-M2G350-A2 to threads
and install the radiator draincock. Tighten the
radiator draincock to 16-20 N(ll (12-15 Ib-ft).
5. Fill and bleed the cooling system and check for
leaks. Refer to Cleaning and Inspection in this
section for procedure.
Water Temperature Indicator Sender Unit

Installation 1. CAUTION: Do not remove the radiator cap
1. Check the radiator draincock to be sure the body (8100) on a hot engine.
is installed loosely on the stem. If the stem is Remove radiator cap to relieve any pressure and
screwed into the body, the radiator draincock then replace radiator cap. This reduces coolant
cannot be installed into the tank opening. loss during sender replacement.
2. Push the loosely assembled draincock assembly 2. Disconnect the temperature sending unit wire at
body into the tank opening until it snaps into the sending unit.
place.
3. Prepare the new temperature sending unit for
3. Tighten the draincock stem by turning clockwise installation by ap~lying the Pi~ Sealant with
to 2-3 N·m (18-27Ib-in) torque. Teflon® D8AZ-19554-A or equivalent meeting
Ford specification WSK-M2G350-A2, or a small
amount of electrically conductive sealer to the
threads.
4. Remove the temperature sending unit from
cylinder head(6049) and immediately install the
new temperature sending unit. Tighten to 11-24
Nem (8-18 Ib-ft).
5. Connect the wire to the temperature sending unit.
6. Refill cooling system to replace lost coolant.
7. Start the engine and check the sending unit
operation.
CCL2174·A
ALL RIGHTS RESERVED
Temperature Sending Unit, 4.9L Engine

Part
A - Tighten to 11-24 Ntrn
(8-18 Lb-Ft)
B - ApR1y P~e Sealant with
Te lon® 8AZ-19554-A or
equivalent meeting Ford
specificatio n
WSK-M2G350-A2 to Hole
Prior to Installation.
K15266-D
Part
1 - Temperature Sending Unit
Connector (Part of 14289)
2 10884 Temperature Sending Unit
(Continued)
ALL RIGHTS RESERVED
Engine Coolant Temperature Sender, 5.al
TEMPERATURE
SENDING UNIT
~....- ~ ~ ~ - 10884
11-24 N-m
(8-18 LB-FT)
K15267-B
Water Temperature Indicator Sender Unit Engine Coolant Temperature Sensor

7.3LDiesel Refer to Section 03-14 for engine control system
engine coolant temperature (ECT) sensor.
1. CAUTION: Do not remove the radiatorcap
(8100) from hot engine.
Loosen radiatorcapto relieve any pressure and Cable, Electrical, Engine Block Heater
then retighten radlalorcap. This reduces coolant Removal and Installation
loss during sender replacement.
1. NOTE: Refer to the following illustrations for
2. Disconnect the temperature sending unit wire at block heater cable routing.
the watertemperatureindicatorsenderunit
(10884). Unplug cable from block heater (6A051).
3. Prepare the new water temperature indicator 2. Remove screw from clip securing battery cables
sender unit for installation by applying the Pipe and block heater wiring (68018) to inner fender
Sealant with Teflon® D8AZ-19554-A or bracket.
equivalent meeting Ford specification 3. Cut and remove tip straps.
WSK-M2G350-A2, or a small amount of
electrically conductive sealer to the threads. 4. Using door trim panel removing tool, remove
cable retainers from brackets and frame (5005).
4. Remove the waterlemperatureindicatorsender
unHfrom cylinder head(6049) and immediately 5. Remove cable from vehicle.
install the new walerlemperatureindicator 6. To install, reverse removal procedure.
senderunit Tighten to 11-24 N~ (8-18 Ib-ft).
5. Connect the wire to the water temperature
indicatorsenderunit
6. Refill cooling system to replace lost coolant.
7. Start the engine (6007)and check the sending
unit operation.

ALL RIGHTS RESERVED
Block Heater 4.9L Block Heater 5.0L and 5.8L
BLOCK HEATER 5.0L AND 5.8L
Part Part
-
FRONT OF VEHICLE
Q4699-A

1 10300 Generator 1 10300 Generator
2 - Core Plug Hole 2 95873-S Strap
(Part of 6010) 3 9A486 Secondary Air Injection
3 14305 Generator Voltage Regulator Pump
Wiring 4 6B018 Block Heater Wiring
4 9A486 Secondary Air Injection 5 14300 Battery to Starter Relay
Pump Cable
5 6A051 Block Heater 6 6A051 Block Heater
6 6B018 Block Heater Wiring 7 11001 Starter Motor
7 14300 Battery to Starter Relay 8 - Core Plug Hole
Cable (Part of 6010)
8 9G427 Secondary Air Injection 9 9H467 Secondary Air Injector Pump
Pump Silencer and Bracket Silencer and Bracket
9 11001 Starter Motor
ALL RIGHTS RESERVED
Block Heater, 7.5L
-
FRONT OF VEHICLE
•
FRONT OF VEHICLE
10
RIGHT
Q4700-A
Part Part
1 14300 Battery to Starter Relay 9 - Left Side Core Plug Hole
Cable (Part of 6010)
2 9A486 Secondary Air Injection 10 6010 Cylinder Block
Pump 11 6B018 Block Heater Wiring
3 6B018 Block Heater Wiring (Left Side)
(Right Side) 12 6038 Front Engine Support
4 95873-S Strap Insulator
5 10655 Battery 13 6731 Oil Filter
6 9G427 Secondary Air Injection 14 8286 Lower Radiator Hose
Pump Silencer and Bracket 15 8005 Radiator
7 6A051 Block Heater 16 190734 AIC Manifold and Tube
8 - Right Side Core Plug Hole
(Part of 6010)
(Continued)
ALL RIGHTS RESERVED
Engine Block Heater Cable Routing, 7.3L Engine
..
FRONT OF VEHICLE
Q42~A
Part Part
1 95873-5 Strap 7 10655 Battery
2 37806-5100 Clip 8 - Locator (Part of 6BO 18)
3 148060 Battery Cable Assembly 9 - Locator (Part of 6BO 18)
4 6B018 Engine Block Heater Wiring 10 6A051 Block Heater
5 14301 Battery Ground Cable 11 5005 Frame
6 N610957-S16 Screw, 6.3 - 1.81 x 13 A - Tighten to 7-9 N·m
(62-79 Lb-In)
(Continued)
Engine Block Heater

1. Open radiator draincock (8 i 15) and remove
coolant from radiator (8005) and engine (6007).
2. Remove block heater (6A051). Note the position
that the element is pointed (eg. 12:00, 6:00, etc.)
3. Clean the inside diameter of the core plug hole
machined surface and hole entrance. Remove
any burrs at the hole entrance to avoid damage to
the a-ring.
4. Cover rubber a-ring and core opening with a
liberal coating of chassis grease
(C1AZ-19590-B, C, D, E or equivalent.
5. Insert block heater in core plug hole in the same
position as it was removed.
6. lighten screw in normal clockwise direction. TYPICAL BLOCK HEATER-8A0&1
J57OQ.A
Torque to 1.6-1.8 N·m (14-16Ib-in).
7. Refill cooling system as outlined in this section.

ALL RIGHTS RESERVED
SERVICE PROCEDURES
Radiator Tank Flange Coolant Condition Check

Aluminum Radiator 1. WARNING: NEVER REMOVE THE RADIATOR
CAP (8100) UNDER ANY CONDITIONS WHILE
Refer to Radiator Core Service procedure in this THE ENGINE (6007) IS OPERATING. FAILURE
section. TO FOLLOW THESE INSTRUCTIONS COULD
RESULT IN DAMAGE TO THE COOLING
SYSTEM OR ENGINE AND/OR PERSONAL
INJURY. TO AVOID HAVING SCALDING HOT
Transmission Oil Cooler Connection Leaks COOLANT OR STEAM BLOW OUT OF THE
RADIATOR (8005), USE EXTREME CARE
Aluminum Radiator WHEN REMOVING THE RADIATOR CAP FROM
Check to see that the fitting nut is fully tightened. If the A HOT RADIATOR. WAIT UNTIL THE ENGINE
leak persists, apply a thin, even coat of Dow Corning HAS COOLED, THEN WRAP A THICK CLOTH
1200 primer or equivalent using a brush. Allow to dry AROUND THE RADIATOR CAP AND TURN IT
for 10 minutes at room temperature. Apply Dow SLOWLY TO THE FIRST STOP. STEP BACK
Corning Silastic 734RTV or equivalent in undiluted WHILE THE PRESSURE IS RELEASED FROM
form around the leaking connection and allow it to dry THE COOLING SYSTEM. WHEN IT IS
for one hour. CERTAIN ALL THE PRESSURE HAS BEEN
NOTE: In-tank transmission oil coolers must not be RELEASED, PRESS DOWN ON THE
replaced. Insead, for aluminum radiators, replace the RADIATOR CAP (STILL WITH A CLOTH),
complete radiator assembly. TURN AND REMOVE.
NOTE: It is not sufficient to inspect only the
coolant in the radiator coolant recovery reservoir
(BAOBO). The coolant in the radiator coolant
Radiator Core and Tank Service, recovery reservoir may not be representative of
the coolant in the rest of the system. For
Copper/Brass Radiators reservoir coolant to be representative of system
CAUTION: Only manufactured or natural gas coolant, engine must have been operated long
torches should be used to perform radiator enough and gotten hot enough for an extensive
repairs. Do not use acetylene. No attempt should exchange of coolant between the radiator and
be made to repair a fractured radiator tank. It the radiator coolant recovery reservoir since the
must be replaced. Tank repairs usually result in last time coolant was added to the radiator
repeated failures due to flexing of the tank coolant recovery reservoir.
caused by pressure increase and decrease.
Allow engine to cool and remove radiator cap.
CAUTION: Do not rod out the copper /brass
2. Inspect coolant in both radiator and radiator
diesel radiator. The tubes have integral
coolant recovery reservoir. Coolant should be a
turbulators embossed into them and damage to
clear green or blue color (depending on make of
the tubes will result.
anti-freeze used).
Conventional soft solder service methods should be
Clear coolant or coolant only a very light green or
used when repairing the copper / brass core.
blue indicates that there is only water or a very
weak anti-freeze mixture in the system. Advise
the owner of the need for the correct 50 / 50
CLEANING AND INSPECTION coolant mixture.
A very muddy brown color indicates an
Radiator Coolant Level Check unauthorized make of stop-leak has been used.
Engine (6007) should be at normal operating This may eventually plug the system causing
temperature. overheating. Advise the owner that the best
course would be to drain the system and repair
In addition to maintaining the correct coolant level, the the original concern, flush the system, and refill
radiator fins must be cleaned and the cooling system with correct 50/50 coolant mixture and, if
inspected periodically for leaks in order to be sure the necessary, Cooling System Stop Leak Pellet
system operates at maximum efficiency. D9AZ-19558-A or Cooling System Stop Leak
Check the cooling system for dirty or rusty Powder E6AZ-19558-A or equivalent meeting
appearance. Dirty or rusty coolant requires specification ESE-M99B170-A.
replacement to protect the cooling system from Make clear to the customer that any stop-leak
corrosion damage. material is not a satisfactory repair for a serious
cooling system concern such as a leaking water
pump (8501), gasket, or radiator.
1995 F-150, F-250, F-350, Bronco, F-S~per Duty Powertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
CLEANING AND INSPECTION (Continued)
A reddish brown color indicates rust in the cooling 6. If chunks of rust are visible on top of the tubes in
system. Advise the customer that the best down-flow radia/orsor in the inlet tank in
course would be to flush the cooling system and cross-flow radiators, flush the cooling system. In
refill with the correct 50/50 coolant mixture. severe cases, it ma~ be necessary to remove the
Ford Premium Cooling System Fluid, radiatorinlet lank (8079) to remove the chunks of
E2FZ-19549-AA or equivalent meeting Ford rust that are blocking the tubes.
specification (ESE-M97844-A and 7. If there is puffy white corrosion around the tubes
ESE-M97843-A) contains corrosion inhibitors. In where they are attached to the core headers,
addition, add 1.4 liters (1.5 qts.) of Heavy Duty flush the system. If there is corrosion on aluminum
Cooling System Additive FW-15 or equivalent radiator parts, there is going to be corrosion on
meeting Ford specification ESN-M99B169-A. aluminum engine parts that come in contact with
An iridescent sheen on the top of the coolant coolant.
indicates a small amount of all entering the In severe cases it will be necessary to remove the
coolant. This is common in high-mileage vehicles. tanks and have a radiator specialty shop remove
3. CAUTION: If there is coolant in the engine oil, the corrosion and determine if the core must be
the cause must be corrected and the oil replaced.
changed or engine damage will occur. 8. Advise the owner of the importance of using the
Check the engine oil on the oilleveldipstick proper 50/50 mixture of water and Ford
(6750) to see if any coolant is entering the engine E2FZ-19549-AA Premium Cooling System Fluid
oil as Indicated by drops of coolant visible in tne or e~uivalent meeting specification
oil or a milk~ appearance to the oil. If the oil ESE-M97B44-A which contains corrosion
checks out OK, inform the customer that, while inhibitors. In addition, add 1.4 liters (1.5 qts.) of
not an immediate problem, the situation should be Heavy Duty Cooling System Additive FW-15 or
closely monitored during routine maintenance. equivalent meeting Ford specification
4. CAUTION: Severe oil leakage to the engine ESN-M998169-A.
coolant, as indicated by a milky appearance 9. If the appearance of the coolant is OK, use a
to the coolant, must be corrected or severe hand-held refractometer, such as Rotunda
engine damage will occur. Optical Antifreeze/Battery Tester 021-00046 or
If the coolant is a milky brown color (like coffee equivalent to verify proper coolant concentration.
with heavy cream) engine oil is entering the The range is: (minimum) 45/55, (maximum)
coolant. On 7.3L Diesel and 7.5L gasoline 60/40.
engines the most probable cause IS a leak in the 10. If the cooling system is found to be low on
engine oil cooler. Remove and inspect to find the coolant, top off only from a premixed solution.
problem. 11. If a weak concentration is found, add straight
If the oil cooler checks out OK the headgasket coolant sparingly until concentration readings are
(6051) may be leaking around the oil within acceptable levels.
passageway to the cylinder head (6049) It will 12. If too strong a concentration is found, remove a
be necessarY to remove the cylinderhead, small volume of coolant and add water sparingly
inspect for Hie problem, and replace the head until coolant readings again fall within the
gasket. If the headgaske/checks out OK, then a specified levels.
crack between an engine oil gallery and the
cooling passageways could be the cause. 13. NOTE: Make sure coolant is thoroughly mixed
Inspect the cylinderblock (6010) and cybiJder before taking readings. This is accomplished by
head. Refer to Section 03-00. running the engine until the water thermostat
opens.
A reddish milky appearance to the coolant
indicates that transmission oil is leaking into the Recheck coolant concentration to make sure the
coolant indicating a leaking transmissionHuid coolant has been brought into the proper
cooler (7A095). concentration.
5. CAUTION: If coolant is found to be entering
the transmission fluid, the cause must be
corrected or transmission damage will occur.
Check transmission fluid to make sure coolant Cooling System Hoses and Clamps
has not mixed into transmission fluid as indicated
by a milky appearance. If it has, it will be 1. NOTE: Remember that the cooling system hoses
necessary to flush /ransmission(700J)and operate under a positive pressure of
replace filter outlined in the appropriate section. approximately 90 kPa (13-16 psi), temperatures
Refer to Group 07. Replace radiator assembly, of over 95 degrees Celsius (200 degrees
flush cooling system, refill transmission, and refill Fahrenheit), and are subject to considerable
cooling system with correct 50/50 coolant and vibration. Any hoses with cuts or deterioration
anti-freeze mixture. should be replaced as they are likely to fail on the
road with the attendant risk of engine damage.

ALL RIGHTS RESERVED

Inspect hoses for:
To drain the radiator, open the radiator draincock
• Visible signs of deterioration such as cracking located at the bottom of the radiator and remove the
or checking. Replace if there is visible radiator cap or supply tank cap. The cylinder block of
deterioration. the V-8 engine is drained by removing the drain plugs
• Swelling near clamps and at hose ends. located on both sides of the cylinder block (6010). The
Replace if there is swelling. 6-cylinder engines have one drain plug located at the
• Oil or oily dirt on hoses from engine oil leaks or right rear of the cylinder block.
careless filling. Clean off oil and oily dirt on If replacing coolant, dispose of old coolant in
hoses. Oil will attack rubber over time. If there accordance with applicable federal, state, and local
is weakening or deterioration of a hose, laws and regulations. Promptly clean up any spilled
replace it. coolant.
• Cuts. If hose is cut other than a very superficial Without degas bottle fill the cooling system by
cut, replace hose. installing the cylinder block drain plug(s) and close the
• Hose contacting metal parts, especially sharp radiator draincock. Disconnect the heater outlet hose
edges. If contacting metal parts, loosen clamps at the water pump (8501) to bleed or release trapped
and relocate hose. In some cases it may be air in the system. When the coolant begins to escape,
necessary to put plastic shielding on hose to connect the heater outlet hose.
protect it. If hose has already been cut or worn, Fill the radiator until the coolant is between the cap
it should be replaced. seal in the filler neck to 38mm (1-1 /2 inches) below
2. NOTE: Reasonably fresh replacement hoses the cap seal. Install radiator cap.
should be used. Replacement hoses which have Start engine, warm up, shut off engine. Allow engine to
been in storage for several years should be cool, remove radiator cap and check coolant level. Fill
checked for ozone-caused hardening. Hoses as required.
which have become hard will be difficult to seal With degas bottle, fill the cooling system by installing
and may break in service. all drain plugs and close the radiator draincock. Fill the
Inspect clamps and tighten to specifications: degas bottle until the coolant level stabilizes at the top
hose of the degas bottle. Start engine, warm up, shut
Description N·m Lb·ln
off engine. Allow engine to cool. Verify that the level is
within the fill range on the bottle.
Radiator Hose Clamp 3 27
(Tangential Screw)
Heater or Bypass Hose Clamp 1.8-2.5 10-22
(Screw Type)
Cooling System, Cleaning
Cooling System Flush Procedure
Radiator Installed
Cooling System, Draining, Filling and
Bleeding SPECIAL SERVICE TOOL(S) REQUIRED
WARNING: DO NOT STAND IN LINE WITH OR Description Tool Number
NEAR ENGINE COOLING FAN aLADE (8600)
WHEN ENGINE (6007) IS RUNNING. Heater Hose Disconnect Tool T85T-18539-AH
WARNING: NEVER REMOVE THE RADIATOR CAP NOTE: When disposing of used coolant, always do so
(8100) UNDER ANY CONDITIONS WHILE THE in accordance with all applicable federal, state and
ENGINE IS OPERATING. FAILURE TO FOLLOW local laws and regulations.
THESE INSTRUCTIONS COULD RESULT IN To remove rust, sludge and other foreign material from
DAMAGE TO THE COOLING SYSTEM OR ENGINE the cooling system, use Ford Premium Cooling System
OR PERSONAL INJURY. TO AVOID HAVING Flush F1 AZ-19A503-A or equivalent meeting Ford
SCALDING HOT COOLANT OR STEAM BLOW OUT specification ESR-M14P7-A. Flush system using
OF THE RADIATOR (8005), USE EXTREME CARE Rotunda Cooling System Flusher 106-00010 Flush Kit
WHEN REMOVING THE RADIATOR CAP FROM A Hardware Package 106-00011, and Drain Kit
HOT RADIATOR. WAIT UNTIL THE ENGINE HAS 106-00015 or equivalent. Removal of such material
COOLED, THEN WRAP A THICK CLOTH AROUND restores cooling efficiency and avoids overheating.
THE RADIATOR CAP AND TURN IT SLOWLY TO
THE FIRST STOP. STEP BACK WHILE THE Always remove the water thermostat (8575) prior to
PRESSURE IS RELEASED FROM THE COOLING pressure flushing. A pulsating or reversed direction of
SYSTEM. WHEN YOU ARE SURE ALL THE flushing water flow will loosen sediment more quickly
PRESSURE HAS BEEN RELEASED, PRESS DOWN than a steady flow in the normal direction of coolant
ON THE RADIATOR CAP (STILL WITH A CLOTH), flow. In severe cases where cleaning solvents will not
TURN AND REMOVE IT. properly clean the cooling system for efficient
operation, use the pressure flushing method. Various
To prevent loss of coolant when draining the radiator, types of flushing equipment are available.
attach a hose on the radiator draincock (8115) and
drain the coolant from the radiator into a clean
container.

ALL RIGHTS RESERVED
Do not back-flush cooling systems that have a water The heater core must be back-flushed separately from
shutoff valve in the heater system, or damage to the the engine cooling system for proper back-flush water
valve can result. flow direction through the heater core.
CAUTION: Do not rod out the copper /brass 7.5L 1. The correct heater core back-flushing procedure
gas radiator (8005) or diesel radiator. The tubes , is as follows:
have integral turbulators embossed into them On F-Series and Bronco vehicles, disconnect the
and damage to the tubes will result. outlet heater water hose (18472) from the water
pump fitting and install a female garden hose-end
fitting adapter in the end of the outlet heater
water hose. Secure with a hose clamp (8287).
2. Connect the female garden hose-end of the outlet
hose clamp to the male end of a water supply
garden hose.
3. Disconnect the heater core inlet hose clamp from
the engine block fitting and allow to drain onto
suitable container.
SECTIONAL 4. If a heater water control valve (18495) is installed
VIEW in the heater core inlet hose clamp,. check to be
certain the heater water control valve is open (no
vacuum).
5. Turn the water supply valve on and off several
times so that the surge action will help to dislodge
larger stubborn particles from the tubes. Allow full
water pressure to flow for approximately five
BOTTOM TOP SIDE
minutes.
SIDE
6. If a heater water control valve is installed in the
heater core inlet hose clamp, apply vacuum to the
water valve vacuum motor to make sure heater
water control valve operates and closes properly
to prevent water leakage. Replace the heater
VIEW SHOWING POSITIONS water control valve if required.
OF TURBULATORS ON BOTH
SIDES OF TUBE 7. Remove the heater water hose and female
garden hose-end adapter from the end of the
021...1A outlet hose clamp and connect the outlet hose
Radiator Removed clamp onto the water pump fitting.
1. CAUTION: Radiator Internal pressure must 8. Connect the inlet heater hose onto the engine
not exceed 138 kPa (20 psi). Damage may block fitting.
result. 9. Fill the cooling system as described in this
Back-flush radiator. Position a high-pressure section.
water hose in lower radiator hose location and 10. Test the system for proper heater performance.
back-flush.
2. Remove water hose connection (8592) and water
thermostat as outlined.
3. Back-flush engine (6007). Position high-pressure
Radiator Cap
hose into engine through water thermostat and 1. Inspect the areas under the vacuum valve and
back-flush engine. rubber seal for rust or dirt particles.
Heater Core Back-Flushing 2. Using warm tap water, raise and clean the
vacuum valve and rubber seals. Thoroughly flush
All engine cooling system flushing and back-flushing away loose rust or dirt particles trapped under
procedures must include a separate back-flushing of the vacuum valve and rubber seal and on the
the heater or air conditioning / heater system heater surfaces of the seals.
core (18476), after the flushing or back-flushing of the
engine cooling system. This will prevent engine cooling 3. Inspect and remove any imbedded rust or dirt
system particles from clogging the heater core tubes particles on the sealing surfaces of the rubber
and reducing (or eliminating) coolant flow through the seal.
heater core.

ALL RIGHTS RESERVED
4. Inspect the radiator filler neck opening for rust or

dirt particles on the sealing surface at the bottom Part
of the filler neck opening. Use a clean cloth and Item Number Description
wipe the sealing surface to remove any rust or 3 - Overflow System Seal with
dirt particles. If paint is observed on the filler neck Recovery System
sealing surface, remove it using paint thinner. (Part of 8100)
4 - Under Vacuum Valve
(Part of 8100)
5 - Sealing Surface
(Part of 8100)
Radiator
Internal Cleaning
Do not use caustic cleaning solutions or copper / brass
radiator cleaning agents on aluminum radiators
(8005). Internal cleaning of the aluminum tubes can be
accomplished with sonic cleaning equipment.
RADIATOR CAP-8100
Fan Blade
WARNING: DO NOT ATTEMPT TO STRAIGHTEN
OR REPAIR FAN. REPLACE FAN BLADE IF
DAMAGED.
Inspect fan for damage or cracking. Cracking is most
likely to occur near the base of each individual blade. If
fan is damaged, replace as outlined in Section 03-05.
RADIATOR FILLER NECK OPENING

(CROSSFLOW SHOWN) SPECIFICATIONS
Q1413-J
Part Refer to the following charts for engine cooling

Item Number Description specifications.
1 - Seal Surface (Part of 8100)
2 - Under Rubber Seal
(Part of 8100)
(Continued)

ALL RIGHTS RESERVED
ENGINE COOLING SYSTEM REFILL CAPACITIES - F-150 THROUGH F-350, BRONCO,

F-SUPER DUTY SERIES
Approximate Capacity
Imperial
El'!glne Vehicle Equipment U.S. Quarts Quarts Liters
4.9l F-150/350,F-Super
Manual and Auto. Trans. - Standard 13 10 12
(300 CID) 1-6 Duty & Bronco
4.9l F-150/350,F-Super Manual Trans. with A I C or Super Cool Auto.
14 11 13
(300 CID) 1-6 Duty & Bronco Trans. with Super Cool or Standard
4.9l F-150/350,F-Super Manual Trans. with A I C and Super Cool Auto.
15 12 14
(300 CID) 1-6 Duty & Bronco Trans. with A I C and Super Cool or just A I C
5.0l
F-150 I 250 Bronco Manual Trans. - Standard 13 10 12
(301 CID) V-8
5.0l Manual and Auto. Trans. with A I C Auto. Trans.
F-150 1250 Bronco 14 11 13
(301 CID) V-8 - Standard
5.0l Manual and Auto. Trans. with Super Cool or
F-150 /250 Bronco 15 12 14
(301 CID) v-a Super Cool and A/C
5.al
F-150/350 Bronco Manual Trans. - Standard 15 12 14
(351 CID) v-a
5.al Auto. Trans. - Standard or A / C, Manual
F-150/350 Bronco 16 13 15
(351 CID) v-a Trans. with A/C
5.al Manual and Auto. Trans. with Super Cool or
F-150/350 Bronco 17 14 16
(351 CID) V-8 Super Cool and A I C
F-250/350,F-Super
7.5l Duty Chassis Cab
All options 18 15 18
(460 CID) V-8 and Motor Home
Chassis Vehicles
F-250 I 350 and
F-Super Duty Chassis
7.3l Diesel All options 23 8 188 21-
Cab and Commercial
Stripped Chassis
a Include 1-1 12 U.S. quarts of supplement coolant additive (FW 15 or equivalent).
COOLING SYSTEM PRESSURE SPECIFICATIONS

Vehicle Operating Pressure Min. Test Pressure
F-150-F-350, F-Super Duty, Bronco 90 kPa (13 psi) (10 psi)
Cooling System Part Numbers/Application In an emergency, ordinary tap water with a low alkali
Chart content may be used provided the system is drained
and flushed and filled with the specified coolant/.water
Refer to Master Parts List for service part numbers mixture as soon as possible. Use only if that
and applications. temperature is above O°C (32°F).
NOTE: 7.3L Diesel engines require a supplemental
coolant additive to provide corrosion protection
consistent with diesel engine characteristics. Without
Coolant Mixture the supplemental additive Motorcraft FW-15 or
Service refill recommendations are 50/50 mixture of equivalent, cylinder wall erosion may occur.
water and permanent coolant/antifreeze such as Ford The recommended quantity of coolant additive when
Premium Cooling System Fluid E2FZ-19549-AA or B refilling the entire cooling system is 1-1/2 quarts.
or equivalent meeting specification ESE-M97844-A Refreshing the coolant mixture with an additionalB oz.
plus 1..41 (1.5 qts) of Heavy Duty Cooling System of Motorcraft FW-15, or equivalent, each 15,000 miles
Additive FW-15 or equivalent meeting Ford (24,000 km) or 12 months is recommended.
specification ESN-M998169-A.
Minimum acceptable coolant / water concentration is TANK TO HEADER CRIMP ASSEMBLED HEIGHT
45 percent antifreeze to 55 percent water. Maximum Radiator Height
acceptable is 60 percent coolant to 40 percent water.
Use only a hand-held refractometer such as Rotunda Aluminum Core 10.9mm
(27/64 inch)
Optical Antifreeze / Battery Tester 021-00046 or
equivalent to check concentration.

ALL RIGHTS RESERVED
03-03-47 Engine Cooling 03-03·47
WATER THERMOSTAT OPENING TEMPERATURE WATER THERMOSTAT OPENING TEMPERATURE

(Cont'd)
Start to Open Fully Open
Engine °C (OF) °C (OF) Start to Open Fully Open
4.9L · · Engine
.
°C (OF)
.
°C (OF)
5.0L
· · 5.8L Super
. .
5.8L
(Continued)
· · 7.5L
7.3L Diesel • 205 • 220
FAN CLUTCH SPECIFICATIONS

Water Pump Fan Test Speed
Engine
RPM
Required
Water toRun Minimum Fan Minimum Fan Water
Pump Water RPM at RPMat Pump
Pulley Pump at Disengagement Engaged Test
Engine Vehicle Equipment Ratio 3000 RPM Temperature Temperature Speed
4.9L F-150/350, with AlC 1.28 2340 1200 @ 125-F 2200 @ 190-F 3880
(300 CID) 1-6 F-Super Duty &
Bronco
4.9L F-150/350, without AlC .98 3960 1200 @ 100-F 2075 @ 165-F 3000
(300 CID) 1-6 F-Super Duty &
Bronco
5.0L F-150/250 Manual Trans. - 1.37 2580 1800 @ 140-F 2800 @ 200-F 3540
(301 CID) v-a Bronco Standard
S.OL F-1S0/2S0 Manual and Auto. 1.37 2190 1400 @ 190-F 24S0 @ 1SS-F 3000
(301 CID) V-8 Bronco Trans. with AlC Auto.
Trans. - Standard
FAN CLUTCH SPECIFICATIONS (Cont'd)

Water Pump Fan Test Speed
Engine
RPM
Required
Water to Run Maximum Fan Minimum Fan Water
Pump Water RPM at RPM at Pump
Pulley Pump at Disengagement Engaged Test
Engine Vehicle Equipment Ratio 3000 RPM Temperature Temperature Speed
7.5L - with AIC 1.25 2400 1900@ 141°F 2600@211°F 3000
(460 CID) V-8
7.5L - without AIC 1.25 2400 1900@ 125°F 2600@ 195°F 3000
(460 CID) V-8
7.3L Diesel F-250 I 350 and All Options 1.1: 1 3000 650@ 122°F 2900@200°F 3300
F-Super Duty
Chassis Cab
and Commercial
Stripped
Chassis

Description N-m Lb·Ft Description N-m Lb·Ft
Radiator Hose Clamp 3-4 27-35 Radiator Top Brackets to Radiator 11-14 8-11
(Double Wire Clamp) (Lb-In) Support, F-150-250-350, F-Super
Duty and Bronco
Radiator Hose Clamp 3 27
(Tangential Screw) (Lb-In) Radiator Top Brackets to Radiator 3-5 27-44
Support, F-Super Duty Stripped (Lb-In)
Radiator Thermostat Housing, All 16-24 12-18
Chassis
Engines Except 7.5L
Radiator to Frame Insulator, 102-142 75-105
Radiator Thermostat Housing, 7.5L 32-37 23-38
F-Super Duty Commercial Chassis
(Continued)
(Continued)
ALL RIGHTS RESERVED
TORQUE SPECIFICATIONS (Cont'd) TORQUE SPECIFICATIONS (Cont'd)

De8crlptlon N·m Lb-Ft De8crlptlon N·m Lb-Ft
Radiator Support to Frame 41-47 30-35 Heater or Bypass Hose Clamp 1.8-2.5 10-22
Insulator Bolts, F-150-250-350, (Screw Type)
F-Super Duty and Bronco
Transmission Oil Line Nut to Fitting 16-24 12-18
Radiator Support to Frame 160-217 118-160 on Radiator, F-Series, F-Super
Insulator Bolts, F-Super Duty Duty and Bronco
Stripped Chassis
Oil Cooler Line Clamps 4-5 35-44
Block Heater Retaining Bolt 1.6-1.8 14-16 (Lb-In)
(Lb-In)
Radiator Draincock to Radiator 16-20 12-15
Fan Shroud to Radiator, 7-10 4-6
Radiator Draincock Stem to 2-3 18-27
F-150-250-350, F-Super Duty and
Radiator Draincock (Lb-In)
Bronco
Radiator Thermostat Housing 27 20
Fan Shroud to Radiator, F-Super 3-5 27-44
7.3L Diesel
Duty Commercial (Lb-In)
Transmission Oil Cooler to 12-15 9-11
Fan Shroud to Radiator, F-Super 6-8 53-71
Radiator Tank (Aluminum Core
Duty Motorhome (Lb-In)
Radiator)
Fan Clutch Assembly to Water 41-136 30-100
Fan to Fan Clutch, 7.3L Diesel 16-24 12-18
Pump,4.9L
Pump, All V-8 Engine Except 7.3L
Pump, 7.3L Diesel
ROTUNDA EQUIPMENT
Water Filter Hose Clip to Air Inlet 28-33 18-23
Housing, 3/8-16 Model De8crlptlon
Water Filter Hose Clip to Engine 40-48 29-36 021-00012 Radiator / Heater Core Pressure Tester
Idler Gear Cover, 3/8-16
021-00046 Battery / Anti-Freeze Tester
Transmission Oil Line Fitting to 24-31 18-23
Radiator, F-Series, F-Super Duty 106-00010 Cooling System Flusher
and Bronco 181-00001 Coolant Quick Change
Water Temperature Indicator 11-24 8-18 105-00051 73 Digital Multimeter
Sender Unit
106-R0011 Flash Kit Hardware Package
Bypass Hose Clamps, 5.0L-5.8L 3-4 27-35
106-R0015 Drain Kit
Bypass Hose Clamps, 7.5L 1.3-2.2 12-20
(Continued)

ALL RIGHTS RESERVED
03-04A-1 Fuel Charging and Controls, 5.0L and 5.8L 03-04A-1
SECTION 03·04A Fuel Charging and Controls, 5.0L and

5.8L
VEHICLE APPLICATION ........•.......••..............•••........03-04A-1 DIAGNOSIS AND TESTING (Cont'd.)
DESCRIPTION AND OPERATION Tips to Avoid Lean Air-Fuel Conditions 03-04A-8
A/C Compressor Clutch Control Relay .•.•..•..........03-o4A-7 REMOVAL AND INSTALLATION
Air Induction System ..•.•..............•.............•.••......03-o4A-3 Fuel Charging System....•.....................................03-o4A-8
Fuel Charging Wiring ........••••••.............•....•........•.03-o4A-6 Post-Service Procedures 03-04A-8
Fuel Injection Supply Manifold ••...........................03-o4A-5 Preservice Procedures ..............•......................03-o4A-8
Fuel Injection Timing ....••..........................•....•..•.•03-o4A-2 Fuel Charging Wiring 03-o4A-14
Fuel Injectors •••••...•.............................•............•..03-o4A-4 Fuel Injection Supply Manifold 03-o4A-12
Fuel Pressure Regulator ....•••••...........•..•..•...........03-o4A-6 Fuel Injectors ••..•...............................................03-o4A-10
Fuel Pressure Relief Valve •....••••••....•........•..........03-o4A-6 Fuel Pressure Regulator 03-o4A-13
Fuel Pump Relay ••.••..••......••...............................•.03-04A-7 Fuel Pressure Relief Valve ..........................•......03-o4A-11
Fuel System 03-o4A-1 Fuel Pump Relay ..........•..•..................................03-o4A·14
Inertia Fuel Shutoff (IFS) Swltch........•••.........•..••••03-o4A-6 Spring Lock Coupling 03-o4A-9
Intake Manifold ••••••••••.........................•....•..........03-o4A-4 Throttle Body .............•.................................•....03-o4A-10
Multiport Fuel Injection (MFI) ...........................•••.03-o4A-3 CLEANING AND INSPECTION
Throttle Body ..•••••••..•..•...•••••••.......................•.....03-o4A-3 Throttle Body .............•......................................03-o4A-14
DIAGNOSIS AND TESTING ADJUSTMENTS
Fuel Charging and Controls ..........•..••..••......•....••.03-o4A-8 Idle Speed ••••..........•..........................................03-o4A-14
Fuel Injector .......•..••.••••..•.......•..•••.•....•........••......03-o4A-8 SPECIFICATIONS ••••.•........••................................••03-04A-15
Testing .•.•..•.........••••...••........•.•••••••••.....•..••.•••••03-o4A-8 SPECIAL SERVICE TOOLS/EQUIPMENT ....••..........03-o4A-15
VEHICLE APPLICATION
Vehicles Equipped with 5.0L and 5.8L MFI V-8 Engines
Fuel System A constant fuel pressure drop is maintained across the

A powertrain control module (PCM)( 12A650) accepts fuel injectors by a fuel pressure regulator (9C968).
input from various engine sensors to compute the The fuel pressure regulator is connected in series with
the fuel injectors and is positioned downstream from
required fuel flow rate necessary to maintain a
prescribed air / fuel ratio throughout the entire engine them. Excess fuel supplied by the pump, but not
required by the engine, passes through the fuel
operational range. The powertrain control module then
outputs a command to the fuel injectors (9F593) to pressure regulator and returns to the fuel tank through
meter the appropriate quantity of fuel. a fuel return line.
The powertrain control module also determines and The SFI system is controlled by the PCM.lf at any
compensates for the age of the vehicle and its time, the PCM malfunctions, or the battery voltage
uniqueness. The system will automatically sense and drops to an abnormal level, fuel injection will occur for
compensate for changes in altitude (i.e., from sea level all cylinders simultaneously once every two
to mountains) and will also permit push-starting the revolutions of the crankshaft.
vehicle should it become necessary (manual The SFI system works in conjunction with the engine
transmission only). control system. This engine control system consists of
The fuel delivery subsystem consists of a the PCM, various sensors, and switches. These
high-pressure in-tank mounted fuel pump and a fuel sensors and switches send input signals to the PCM.
filter / reservoir delivering fuel from the fuel tank Based upon these input signals, the PCM controls the
through a 20 micron fuel filter to a fuel injection supply timing and duration (pulse width) of each injection.
manifold (9F792).
The fuel injection supply manifold incorporates
electrically actuated fuel injectors mounted directly
above each of the engine's intake ports. The fuel
injectors, when energized, spray a metered quantity of
fuel into the intake air stream.
ALL RIGHTS RESERVED
Fuel Injection Timing Electronic Fuel Injection, 5.0L and 5.8L MFI Engine
One group of four fuel injectors (9F593) is energized
simultaneously, once every crankshaft revolution ~
followed by the second group of fuel injectors in the FRONT OF ENGINE
next crankshaft revolution. The period of time that the
fuel injectors are energized (fuel injector "on time" or
pulse width) is controlled by the powertrain control
module (PCM)( 12A650). The powertrain control
module receives input from various engine sensors
and uses this information to compute the required fuel
flow rate necessary to compute the prescribed
air /fuel ratio for the given engine operation. The
powertrain control module determines the needed
injector pulse width and outputs a command to the fuel
injector to meter the exact quantity of fuel.
Fuel Injection Timing 5.0L and 5.8L California
For fuel injection timing:
• Each fuel injector is energized once every other
crankshaft revolution in sequence with engine firing
order.
• The period of time that the fuel injectors are
energized (injector "on time" or pulse width) is
controlled by the vehicle's powertrain control
module powertrain control module.
• Air entering the engine is monitored by mass air
flow, pressure and temperature sensors.
• The outputs of the electronic engine control sensors
are processed by the powertrain control module.
• The powertrain control module determines the
needed fuel injector pulse width and outputs a
command to the fuel injectors to meter the exact
quantity of fuel.
Part
2 - Throttle Linkage
(Part of 9E926)
4 9F483 EGRValve
6 9C968 Fuel Pressure Regulator
7 - Crossover Tube
(Part of 90280)
10 9F792 Fuel Injection Supply
Manifold

ALL RIGHTS RESERVED
03-04A-3 Fuel Charging and Controls, 5.0L and 5.8L 03·04A·3
Multipart Fuel InJection (MFI) Upper Intake Manifold and Throttle Body
Assemblies
The multiport fuel injection system (MFI) is classified
as a multi-point, pulse time, speed density control, fuel
injection system. Fuel is metered into each intake port
in accordance with engine demand.
Sequential Multiport Fuel Injection (SFI) 5.0L
Automatic Transmission and 5.8L California
The sequential multiport fuel injection system is
classified as a multi-point pulse time, mass airflow
controlled, fuel injection system. Fuel is metered into
each intake port in a sequential firing order. Fuel
injectors pulse to follow engine firing order in
accordance with engine demand through fuel injector
nozzle tips mounted on a tuned intake manifold.
Air Induction System

The air induction system supplies filtered air to the
engine to mix with the fuel for combustion purposes.
The air induction system consists of an engine air
cleaner intake tube and duct (9A673), air cleaner
assembly with filter, air cleaner outlet tube, mass
airflow sensor, (on SFC units) throttle body inlet tube,
throttle body (9E926) and intake plenum.
Throttle Body
Part
The throttle body (9E926) controls airflow to the
engine through a double butterfly-type valve. The Item Number Description
throttle position is controlled by a multiple-link, 1 N803469-S 100 Screw and Washer
progressive opening, throttle linkage. The throttle Assembly (2 Req'd)
body is a single-piece die casting made of aluminum. It 2 9B989 Throttle Position Sensor
has a dual bore with an air bypass channel around the 3 56524-S8 Bolt, 5/16-18 x 1.5 (4 Req'd)
throttle plate. This bypass channel controls both cold 4 9E936 Throttle Body Gasket
and warm engine idle airflow as regulated by an idle air 5 9424 Intake Manifold, Upper
control valve (lAC valve)(9F715) assembly mounted 391252-S2
6 Screw
directly to the throttle body. The idle air control valve
7 N605733-S100 Bolt, M6 x 20
assembly is an electro-mechanical device, controlled
by the powertrain control module (PCM)( 12A650) that 8 9F715 Idle Air Control Valve
meters the amount of air bypassed around the throttle 9 9F670 lAC Valve Gasket
plates in order to control engine idle speed. Engine A - Tighten to 1-2 N·m
coolant is diverted through the throttle body mounting (9-18 Lb-In)
pad to improve cold weather operation. B - Tighten to 16-24 N·m
(12-18 Lb-Ft)
Other features of the throttle body include:
1. A pre-set stop to locate the WOT position.
2. A throttle body-mounted throttle position sensor
(TP sensor)(9B989).
3. A sealant / coating that is applied to the
downstream side of the throttle body plate and
bore to minimize closed plate to bore airflow. This
sealant / coating should not be removed or
cleaned.
ALL RIGHTS RESERVED
~ Throttle Body, 5.8L MFI, 5.0L MFI Similar
CANISTER
PURGE
PORTS (5.8L 0/8500 GVW ONLY) V8894-C
V47~
Intake Manifold
The intake manifold (9424) is a two-piece (upper and
lower) aluminum casting. Runner lengths are tuned to
optimize engine torque and power output. The intake
manifold provides mounting flanges for the throttle Fuel InJectors
body (9E926), fuel injection supply manifold (9F792) The eight fuel injectors (9F593) are
and accelerator control bracketry and the EGR valve electro-mechanical devices which both meter and
and supply tube. Vacuum taps are provided to support atomize fuel delivered to the engine. The multiport fuel
various engine accessories. Pockets for the fuel injectors are mounted in the lower intake manifold
injectors (9F593) are machined to prevent both air (9424) and are positioned to direct fuel just ahead of
and fuel leakage. The pockets in which the fuel the engine intake valves (6507). The injector consists
injectors are mounted are placed to direct the injector of a solenoid and valve assembly. An electrical control
fuel spray immediately in front of each engine intake signal from the powertrain control module
valve (6507). (PCM)( 12A650) activates the injector solenoid,
causing the needle to move inward off the seat, .
allowing fuel to flow. Since the injector flow orifice is
fixed and the fuel pressure drop across the fuel
injector is constant, fuel flow to the engine is regulated
by how long the solenoid is energized. Atomization is
obtained by a director metering plate at the point
where the fuel separates.

ALL RIGHTS RESERVED
All vehicles equipped with 5.0L and 5.8L MFI engines

have deposit resistant injectors (ORI) installed. This Part
fuel injector is designed to eliminate the lean fuel Item Number Description
delivery concerns which occur with conventional 4 - Armature (Part of 9F593)
multiport fuel injectors when low grade, non-detergent 5 - Washer (Part of 9F593)
fuels are used. 6 - Lower Intake Manifold
O-Ring (Part of 9F593)
7 - End Cap
(Part of 9F593)
8 - Stainless Steel Valve Body
(Part of 9F593)
9 - Stainless Steel Needle
(Pintle) (Part of 9F593)
10 - Electrical Connector
(Part of 9F593)
Fuel Injection Supply Manifold

The fuel injection supply manifold (9F792) delivers
high pressure fuel from the vehicle fuel supply line to
the eight fuel injectors (9F593). The assembly
consists of two banks of tubular fuel injection supply
manifolds connected by two permanent crossover
connections, eight injector connectors, a mounting
flange to the fuel pressure regulator and mounting
attachments which locate the fuel manifold assembly
and provide fuel injector retention. The fuel inlet and
outlet connections have push-connect fittings. The unit
is serviced as an assembly only.
FUEL PRESSURE
REGULATOR
9C968
FUEL PRESSURE
RELIEF VALVE
9H321
A19017-A
Part
Item
1
3
-
-
-
(Continued)
Number Description
Supply Manifold O-Ring
(Part of 9F593)
Integral Filter
(Part of 9F593)
Coil (Part of 9F593)
..
FRONT OF ENGINE
TO
INJECTOR V5301-D

ALL RIGHTS RESERVED
Fuel Pressure Regulator Fuel Pressure Relief Valve

The fuel pressure regulator (9C96a) is attached to the The fuel pressure relief valve (9H321) is used to
fuel injection supply manifold (9F792) downstream of relieve fuel pressure from the fuel system. The fuel
the fuel injectors (9F593). It regulates the fuel pressure relief valve is located on the fuel injection
pressure supplied to the fuel injectors. The fuel supply manifold (9F792). For fuel system pressure
pressure regulator is a diaphragm-operated relief relief procedures, refer to Section 10-01 A.
valve in which one side of the diaphragm senses fuel
pressure and the other side is subjected to intake FUEL PRESSURE
manifold vacuum. The nominal fuel pressure is REGULATOR
established by a spring preload applied to the 9C968
diaphragm. Balancing one side of the diaphragm with FUEL PRESSURE
RELIEF VALVE
manifold pressure maintains a constant fuel pressure 9H321
drop across the fuel injectors. Fuel in excess of that
used by the engine is bypassed through the fuel
pressure regulator and returns to the fuel tank (9002).
FRONT OF ENGINE
TO
~ INJECTOR
V5301-D
Fuel Charging Wiring

The fuel charging wiring (90930) connects the engine
wire harness to each fuel injector (9F593) and other
electronic engine controls such as throttle position
sensor (TP sensor)(9B989) and idle air control valve
(lAC valve)(9F715). The fuel charging wiring receives
fuel injector actuation signals from the powertrain
control module (PCM)( 12A650) and transfers the
signals to the fuel injectors. The signals from the
V7787-C powertrain control module determine the fuel injection
sequence and duration each fuel injector will stay open
Part to allow fuel into the combustion chambers.
1 - Engine Vacuum Reference
Tube (Part of 9C96a)
Inertia Fuel Shutoff (IFS) Switch
2 - Ball Seat (Part of 9C96a)
3 - Spring (Part of 9C96a) The inertia fuel shutoff switch (IFS switch)(9341) is
4 - Upper Housing used in conjunction with an electric fuel pump. The
(Part of 9C96a) purpose of the inertia fuel shutoff switch is to shut off
5 - Diaphragm (Part of 9C96a) the fuel pump in the event of a collision. It consists of a
steel ball held in place by a magnet. When a sharp
6 - Lower Housing
impact occurs, the ball breaks loose from the magnet,
(Part of 9C96a)
rolls up a ramp and strikes a target plate which opens
7 - Fuel Outlet Tube (Return)
the electrical contacts of the inertia fuel shutoff switch
(Part of 9C96a)
and shuts off the fuel pump. Once the inertia fuel
a Fuel Inlet Tube (Supply)
(Part of 9C96a) shutoff switch is open, it must be manually reset
before restarting the vehicle.
9 - O-Ring Groove
(Part of 9C96a)
10 - Mounting Plate
(Part of 9C96a)
11 - Fuel Filter Screen
(Part of 9C96a)
12 - Spring Seat (Part of 9C96a)
13 - Valve Assembly
(Part of 9C96a)

ALL RIGHTS RESERVED
03·04A·7 Fuel Charging and Controls, 5.0L and 5.8L 03-04A-7
...I nertia f.y-ei Shutoff Switch

Part
3 - Target Plate (Part of 9341)
4 - Ball (Part of 9341)
5 - Magnet (Part of 9341)
6 - Reset Button Position for
Open Switch (Part of 9341)
7 - Closed Switch (Part of 9341)
Fuel Pump Relay

The fuel pump relay supplies power to the fuel pump
when the powertrain control module (PCM)( 12A650)
grounds the relay during START and engine RUNNING
conditions.
AI C Compressor Clutch Control Relay

The A I C compressor clutch control relay is used to
improve idle smoothness after engine start-up and to
improve acceleration performance. The A/C is cut off
for approximately 5 seconds just after the engine is
started and when the throttle position sensor indicates
EXTERNAL VIEW A23669-A a wide open throttle condition.
Part
1 - Electrical Contacts
(Part of 9341)
2 - Switch Terminals
(Part of 9341)
(Continued)

ALL RIGHTS RESERVED
03·04A·8 Fuel Charging and Controls, 5.0L and 5.8L 03·04A·8
Fuel Charging and Controls Preservice Procedures

Refer to the Powertrain Control/Emissions Diagnosis The fuel charging assembly consists of the throttle
Manual (OBD-I). 1 body (9E926), and the upper and lower intake
manifolds (9424). Prior to service or removal of the
fuel charging assembly, the following steps must be
taken:
Tips to Avoid Lean Air-Fuel Conditions 1. Disconnect battery ground cable battery lead and
Rough idle, hesitation, poor throttle response, secure it out of the way. Remove the fuel supply
induction backfire and stalls during cold manifold shield (9J314).
start/warm-up may be caused by the poor volatility of 2. Remove engine air cleaner intake tube and duct
some high octane premium grade unleaded fuels (91 (9A673) from air cleaner to throttle body.
octane or higher [R+M]/2). When com~ared to
3. Remove fuel tank filler cap (9030) to relieve tank
regular grade unleaded fuel (87 octane l R+M] / 2),
pressure.
high octane premium grade unleaded fuel may cause
long crank time. 4. Release pressure from fuel system at fuel
pressure relief valve (9H321) (Schrader) on
Use a regular grade unleaded fuel in all vehicles,
intake manifold. Use Multiport Fuel Injection Fuel
except where a premium unleaded fuel is
Pressure Gauge (EFI/CFI) T80L-9974-B. To gain
recommended in the owner guide. If lean air-fuel type
access to fuel pressure relief valve, valve cap
symptoms are experienced, determine the grade and
must first be removed.
brand of fuel used and offer the following service tips.
Post-Service Procedures
• Advise those using a higher octane grade fuel to
switch to a regular grade unleaded fuel. For those After the service is complete and the fuel charging
using a regular grade fuel, advise them to try assembly is installed onto engine, the following steps
another brand. must be taken:
• Do not advise using a higher octane unleaded fuel 1. Install engine air cleaner intake tube and duct to
, than is recommended for that specific engine. Ford throttle body.
engines are designed to perform best using a high 2. Install the fuel tank filler cap.
quality regular grade unleaded fuel.
3. Connect battery ground cable.
• Only advise using a higher octane unleaded fuel to
avoid potentially damaging spark knock or ping, but 4. NOTE: Check all connections at fuel rails,
do so only after mechanical repairs are ineffective. push-connect fittings, fuel injectors, etc.
• All unleaded gasolines used should contain

CAUTION: The fuel system is normally
detergent additives that are advertised as having
pressurized to 276 kPa (40 psi).
"keep clean" or "clean up" performance for intake Turn ignition switch (11572) on and off several
valves (6507) and fuel injectors (9F593). times without starting engine to pressurize the
fuel system. Check for fuel leaks at fuel pressure
regulator (9C968), fuel injectors (9F593) and fuel
connect fittings.
Fuel Injector 5. Start engine and warm to operating temperature.
Check for coolant leak if coolant was removed.
Testing Refer to Symptom Chart and Pinpoint Test A in
Test fuel injectors (9F593) using Rotunda Fuel Injector Section 03-03.
Tester / Cleaner 1113-00001 or equivalent. Follow tool
manufacturer's operating instructions.
Fuel Charging System

Multipart Fuel Injection Fuel Pressure T80L-9974-B
Gauge (EFI / CFI)

ALL RIGHTS RESERVED
03-04A·9 Fuel Charging and Controls, 5.0L and 5.8L 03·04A·9
6. Perform EEC self test to check system's function.

Refer to Powertrain Control/Emissions Diagnosis
2
Manual. Recheck for fuel leaks.
Spring Lock Coupling

SPECIAL SERVICE TOOL(S) REQUIRED ®
Description
Spring Lock Coupling Disconnect Tools
Tool Number
T81 P-19623-G 1
------------------
Spring Lock Coupling Disconnect Tools T81 P-19623-G2
The spring lock coupling is a fuel line coupling held

together by a garter spring inside a circular cage. ®
~henthecoupling~conn~t~,theflaredendofthe ~~ ~~ ~_~~_ _~ ~
female fitting slips behind the garter spring inside the
cage of the male fitting. The garter spring and cage
then prevent the flared end of the female fitting from
pulling out of the cage. As a redundant locking feature,
a horseshoe shaped retaining clip is incorporated to
improve the retaining reliability of the spring lock ©
coupling.
CUPITETHER ASSY
------------------
MALE
FrmNG
SPRING-LOCK
COUPLING
@ V4803-D
1. Release fuel system pressure. Refer to Section 1. Make sure the garter spring is in cage of male
10-01 A for fuel system pressure relief fitting. If garter spring is missing, install a new
procedures. A fuel pressure relief valve (9H321) spring by pushing it into cage opening. If garter
on the fuel injection supply manifold (9F792) is spring is damaged, remove it from cage with a
provided for this proc~ure. small wire hook (do not use a screwdriver) and
2. Remove retaining clip from spring lock coupling install a new spring.
by hand only. Do not use any sharp tool or 2. WARNING: USE ONLY THE SPECIFIED
screwdriver as it may damage the spring lock O-RINGS AS THEY ARE MADE OF A SPECIAL
coupling. MATERIAL. THE USE OF ANY O-RING OTHER
3. Twist fitting to free it from any adhesion at the THAN THE SPECIFIED O-RING MAY ALLOW
O-ring seals. THE CONNECTION TO LEAK
INTERMITTENTLY DURING VEHICLE
4. Using Spring Lock Coupling Disconnect Tool OPERATION.
T81 P-19623-G 1 (3/8 Inch) or T81 P-19623-G2
(1 /2 Inch), disconnect fuel hoses at the fuel rail Clean all dirt or foreign material from both pieces
supply tube and fuel rail return tube. of coupling.
a. Fit tool to coupling so tool can enter cage to 3. Replace missing or damaged O-rings. Use only
release garter spring. O-rings list~ in Spring Lock Coupling illustration.
b. Push the tool into the cage opening to release 4. Lubricate male fitting and O-rings and inside of
female fitting from garter spring. female fitting with clean engine oil
XO-1 0~3O-QSP or equivalent meeting Ford
c. Pull the coupling male and female fittings sp~ification ESE-M2C 153-E.
apart.
5. Fit female fitting to male fitting and push until
d. Remove the tool from the disconnect~ garter spring snaps over flared end of female
coupling. fitting.

ALL RIGHTS RESERVED
6. Check coupling engagement by pulling on fitting 6. Remove and discard gasket between throttle
and visually checking to make sure garter spring body and upper intake manifold.
is over flared end of female fitting.
7. NOTE: All vehicles require the large black clip to THROTTLE
be installed on the supply side fuel line and the BODY
small gray clip to be installed on the return side 9E926
fuel line.
Position retaining clip over metal portion of spring
lock coupling. Firmly push retaining clip onto
spring lock coupling. Make sure horseshoe
portion of clip is over the coupling. Do not install
retaining clip over rubber fuel line.
Throttle Body
Removal
cable from ball stud, use a screwdriver or
similar tool close to the stud and pry slowly.
Pulling by hand may damage the cable.
Disconnect throttle linkage at throttle ball.
Disconnect C6 (5.8l only) transmission linkage
from throttle body (9E926).
2. Disconnect throttle position sensor and idle air Installation
control valve wiring connectors. 1. NOTE: If scraping is necessary, be careful not to
3. Remove engine coolant hose connectors and damage gasket surfaces of throttle body and
vacuum lines as necessary. intake manifolds, or allow gasket material to drop
into manifold.
4. Remove four throttle body bolts.
Make sure that both throttle body and upper
intake manifold gasket surfaces are clean.
2. Install throttle body gasket on the four studs of
the upper intake manifold.
THROTTLE 3. Install throttle body to upper intake manifold.
BODY
9E926 4. Secure throttle body to upper intake manifold with
four retaining bolts. Tighten to 16-24 N·m (12-18
Ib-ft).
5. Reinstall engine coolant hoses and vacuum
connections as necessary.
6. Connect air control valve and throttle position
(TP) sensor electrical connectors.
7. Connect throttle cable and transmission linkage
to throttle body.
Fuel Injectors
BOLT (4)
Removal
1. Perform all preservice procedures as described
in this section.
2. Remove upper intake manifold (9424) and fuel
injection supply manifold (9F792) as described in
V4796-H
this section.
5. Carefully separate throttle body from upper

intake manifold (9424).

ALL RIGHTS RESERVED
03·04A·11 Fuel Charging and Controls, S.Ol and S.8l 03·04A·11
3. Carefully remove electrical harness connectors

from individual fuel injectors (9F593) as required.
ELECTRICAL
CONNECTOR
O-RING
.SEALS
FUEL
INJECTOR
9F593
Installation
V4809-C
1. CAUTION: Never use silicone grease. It will
4. Grasping fuel injector nozzle tip body, pull up clog the fuel Injectors.
while gently rocking injector from side to side. lubricate new O-rings with light 10W-30 or
equivalent oil meeting Ford specification
ESE-M2C 153-E and install two on each injector.
2. Install fuel injectors using light, twisting, pushing
motion.
3. Install fuel injection supply manifold as described
in this section.
4. Install electrical harness connectors to fuel
injectors.
section. Perform all post-service procedures as
Fuel Pressure Relief Valve

V481o-e
5. NOTE: Deposit resistant injectors (DRI) do not Description Tool Number
need to be cleaned. Multipart Fuel Injection Fuel Pressure T80L-9974-B
Inspect fuel injector O-rings (two per injector) for Gauge (EFI / eFI)
signs of deterioration. Replace as required.
1. NOTE: Fuel pressure relief valve cap (9H323) on
fuel pressure relief valve (9H321) must be
removed.
If fuel injection supply manifold (9F792) is
mounted to engine, remove fuel tank filler cap
(9030), then release pressure from system at fuel
pressure relief valve on fuel injection supply
manifold, using Multiport Fuel Injection Fuel
Pressure Gauge (EFI / CFI) T80l-9974-8.
2. Using an open-end wrench or suitable deep-well
socket, remove fuel pressure relief valve.
Installation
1. Install fuel pressure relief valve and fuel pressure
relief valve cap. Tighten fuel pressure relief valve
to 7.75 N·m (66 Ib-in) and the fuel pressure relief
valve cap to 0.6 N·m (5.3Ib-in).
1995 F-150, F-250, F-350, Bronco, F-SuperDuty Powertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
03-04A-12 Fuel Charging and Controls, S.Ol and S.8l 03-04A-12
~ Fuel Injection Supply Manifold

Spring Lock Coupling Disconnect Tool T81 P-19623-G 1
Spring Lock Coupling Disconnect Tool T81 P-19623-G2
Removal @
1. Perform all preservice procedures as described
in this section.
described in this section. Refer to Section
03-018.
3. Disconnect fuel supply and return line retaining
clips.
®
4. Using Spring Lock Coupling Disconnect Tool
T81 P-19623-G 1 (3/8 Inch) or T81 P-19623-G2
(1 /2 Inch), disconnect the fuel chassis inlet and
outlet fuel hoses from the fuel supply manifold as
follows:
a. Fit tool to coupling so that tool can enter cage
opening to release the garter spring.
©
b. Push the tool into the cage opening to release
the female fitting from the garter spring.
c. Pull the coupling male and female fittings
apart.
d. Remove the tool from the disconnected
coupling.
@ V4803·D
FUEL SUPPLY MANIFOLD

SUPPLY TUBE
FUEL SUPPLY MANIFOLD

RETURN TUBE
V4805·G

ALL RIGHTS RESERVED
5. Remove four (two per group) fuel supply manifold 3. Secure the fuel injection supply manifold using
retaining bolts. four retaining bolts. Tighten to 8-12 N·m (71-106
Ib-in).
4. Connect the fuel inlet and outlet lines at the fuel
injection supply manifold connections as follows:
a. Check for missing or damaged garter spring,
remove damaged spring with smatl hooked
wire, and install new spring.
b. Clean fittings with solvent. Check for missing
or damaged O-rings. Replace missing
O-rings. If either a-ring is damaged, replace
both.
c. Assemble fitting by pushing with a slight
twisting motion.
d. To check coupling engagement, pull on fitting
and visually check to be sure garter spring is
over flared end of female fitting.
BOLT BOLT
V4806-D
GARTER
6. NOTE: Fuel injectors (9F593) will stay in fuel SPRING
19E576
injection supply manifold (9F792) when removed.
Remove manifold.
DISENGAGE FUEL
INJECTORS AT
LOWER MANIFOLD V4807-D
Installation
1. Make sure injector end caps are clean and free of
contamination.
2. Install fuel injectors into fuel injection supply
manifold, then seat fuel injectors into pockets in V5908-D
lower intake manifold. Make sure the fuel
injectors are properly seated. 5. Connect fuel line retaining clips.
section.
Fuel Pressure Regulator

Removal
1. Perform all preservice procedures if removing
fuel pressure regulator (9C968) while fuel
injection supply manifold (9F792) is installed on
ENGAGE FUEL
INJECTORS AT engine.
LOWER MANIFOLD
2. Remove vacuum line at fuel pressure regulator.
Va&5-D

ALL RIGHTS RESERVED
03-04A-14 Fuel Charging and Controls, 5.0l and 5.8l 03-04A-14
3. Remove two Allen head retaining screws from Fuel Charging Wiring
regulator housing.
4. Remove fuel pressure regulator, return seal and
both O-rings. Discard return seal and inspect 1. Remove upper intake manifold as described in
O-rings for signs of cracks or deterioration. this section.
5. If scraping is necessary, be careful not to damage 2. Disconnect fuel charging wiring (9D930) from fuel
fuel pressure regulator or fuel supply line O-ring injector (9F593) and electronic engine controls.
surfaces. 3. Remove fuel charging wiring ground strap
retainer nut and ground strap.
4. Disconnect fuel charging wiring from engine
control sensor wiring.
For installation, follow removal procedures in reverse
order. Verify all connections.
Fuel Pump Relay

2. Locate relay (14N089), located in the engine
compartment power distributor center, and
remove relay.
Installation CLEANING AND INSPECTION

1. Lubricate fuel pressure regulator O-ring with
10W-30 or equivalent oil meeting Ford
specification WSE-M2C903-A2.
Throttle Body
NOTE: The throttle body (9E926) for this vehicle is a
2. Make sure O-ring surfaces of fuel pressure
sludge resistant design and should not be cleaned.
regulator and fuel injection supply manifold are
clean.
3. Install O-rings and new return seal on fuel ADJUSTMENTS
pressure regulator.
4. Install fuel pressure regulator on fuel injection
supply manifold. lighten two retaining screws to
Idle Speed
3-5 N·m (27-44 Ib-in). Refer to Powertrain Control/Emissions Diagnosis
Manual 3 (080-1) for idle speed adjustment
5. Install vacuum line to fuel pressure regulator.
procedures.
6. Perform all post-service procedures as described
in this section.

ALL RIGHTS RESERVED
03·04A·15 Fuel Charging and Controls, 5.0L and 5.8L 03·04A·15
SPECIFICATIONS
TORQUE SPECIFICATIONS ROTUNDA EQUIPMENT
Description N·m Lb-In Model Description

Lower Intake Manifold to Head 31-34 23-25 113-00001 Fuel Injector Tester
(Lb-Ft)
EGR Valve to Upper Intake Manifold 17-25 13-19
(Lb-Ft)
Cooling Manifold 4-5.6 35-50
Upper Intake Manifold to Lower 16-24 12-18
Intake Manifold Bolts (Lb-Ft)
Throttle Body to Upper Intake 16-24 12-18
Manifold (Lb-Ft)
Idle Air Control Valve (lAC) to 8-12 71-106
Throttle Body
Throttle Position (TP) Sensor to 28-38 25-34
Throttle Body
Fuel Pressure Regulator to Fuel 3-5 27-44
Injection Supply Manifold
Fuel Injection Supply Manifold to 8-12 71-105
Lower Intake Manifold
Coil Bracket to Manifold Stud 6-7 53-62
Throttle Cable Bracket to Manifold 11-13 8-10
(Lb-Ft)
Fuel Pressure Relief Valve 7.75 69
Fuel Pressure Relief Valve Cap 0.6 5.3
SPECIAL SERVICE TOOLS REQUIRED

Tool Number/
T80L-9974-B
Multiport Fuel Injection Fuel
Pressure Gauge (EFI / CFI)
T80L-9974-8
T81 P-19623-G2
Disconnect Tool (1/2 Inch)
T81 P-18823-G2
T81 P-19623-G 1
Disconnect Tool (3/ 8 Inch)
T81 P-19823-G1
ALL RIGHTS RESERVED
03-048-1 Fuel Charging and Controls, 4.9L 03-048-1
SECTION 03·048 Fuel Charging and Controls, 4.9L

VEHICLE APPLICATION ..................•..................•..•..03-04B-1 REMOVAL AND INSTALLATION (Cont'd.)
DESCRIPTION AND OPERATION Post·Service Procedures............••........•........•..03-o4B-8
Air Induction System ..•................•.•..•.•.............•..03-o4B-2 Preservice Procedures .........................•.......•.•.03-04B-8
Fuel Charging Wiring ..•.•................•..................•..03-048-7 Fuel Charging Wiring ...........•.............•..•..•.....•...03-04B-16
Fuel Injection Supply Manifold ..•..................•.......03-048-6 Fuel Injection Supply Manifold ...•..•..................•.03-048-13
Fuel Injection TIming - MFI Engines ........•..........03-o4B-4 Fuel Injector ........•..•................•....................••...03-048-12
Fuel Injection TIming - SFI Engines...............•....03-04B-4 Fuel Pressure Regulator ..................•................•03-o4B-15
Fuel Injectors ...•.•.••..................•........•.................03-o4B-6 Fuel Pressure Relief Valve ..............•..................03-048-13
Fuel Pressure Regulator .••••.•.•.•..•.•.....•••.•.••...•....•03-048-7 Fuel Pump Relay •.•..•...•......••••.....•..•.....•.••••••.•..••03-048-18
Fuel Pressure Relief Valve ....•........••...............•.••.03-o4B-7 Idle Air Control Valve Assembly........•..•..............03-04B-11
Fuel System - MFI .•................•................•.........03-o4B-1 Spring Lock Coupling ......................................•..•03-o4B-9
Fuel System - SFI ...•.••..................•.•........•....•....03-o48-1 Throttle 80dy ........•.........•....................••...........03-048-10
Intake Manifold ....••.•......••.•......................•..........03-048-5 Throttle Position Sensor ..........•.•...............••..•.••03-048-11
Throttle 80dy ...........•...........•...•..•.•.............••......03-o4B-4 CLEANING AND INSPECTION
DIAGNOSIS AND TESTING Idle Air Control Valve .....................•.•....•...........•03-048-18
Fuel Charging and Controls .•...............................03-o4B-8 Throttle 80dy .........•................•.•...................•...03-048-18
Fuel Injectors ••..••....•.••••••.•••.•..••.•••••••.•..•..•••••.•••.•03-048-8 ADJUSTMENTS
Testing •.......•...•.••........................•....•.•..........•.03-048-8 Idle Speed ..•...............................•.•.........•.........•03-04B-19
REMOVAL AND INSTALLATION SPECiFiCATIONS ..•.........................................•.•...03-048-19
Fuel Charging System.....•.............•.•...............•..•.03-048-8 SPECIAL SERVICE TOOLS/EQUIPMENT ....•.••...•....03-048-19
VEHICLE APPLICATION
Vehicles Equipped with 4.9L MFI and SFI Engines
Fuel System - MFI The powertrain control module also determines and
A Multiport Fuel Injection System is used on 4.9L compensates for the age of the vehicle and its
uniqueness. The system will automatically sense and
engines with 49-state and Canada emissions
certification. compensate for changes in altitude and will also permit
push-starting the vehicle should it become necessary
The Multiport Fuel Injection System (MFI) is classified (manual transmission only).
injection system. Fuel is metered into each intake port The fuel delivery subsystem consists of a
high-pressure in-tank mounted fuel pump (9350) and a
in a sequential firing order. The fuel injectors are
mounted in the runners of the tuned intake manifold fuel filter f reservoir delivering fuel from the fuel tank
(9424) so they spray toward the intake valves (6507). (9002) through a 20 micron fuel filter to a fuel injection
The length of the fuel injector pulse, the time during supply manifold (90280).
which it sprays fuel, is varied by the powertrain control The fuel injection supply manifold incorporates
module (PCM)( 12A650) to control engine speed and electrically actuated fuel injectors directly above each
fuel f air mixture. of the engine's intake ports. The fuel injectors, when
The powertrain control module accepts input from energized, spray a metered quantity of fuel into the
various engine sensors to compute the required fuel intake air stream. The amount of fuel entering the
flow rate necessary to maintain a prescribed air ffuel cylinder is increased or decreased by varying the time
ratio throughout the entire engine operational range. the fuel injector is held open. The injector opening area
The computer then outputs a command to the fuel or injector fuel pressure (psi) does not vary.
injectors to meter the appropriate quantity of fuel.
Fuel System - SFI The Sequential Multiport Fuel Injection (SFI) system is
A Sequential Multiport Fuel Injection (SFI) system is classified as a multi-point, pulse time fuel injection
used on 4.9L engines with California emissions system. Fuel is metered into each intake port in
certification. sequence with the engine firing order. The fuel is
pulsed through six fuel injectors mounted on a tuned
intake manifold (9424). Fuel amount is determined by
engine demand.

ALL RIGHTS RESERVED
An on-board powertrain control module A constant fuel pressure drop is maintained across the
(PCM)( 12A650) accepts input from various engine fuel injectors by a fuel pressure regulator (9C968).
sensors to compute the required fuel flow rate The fuel pressure regulator is connected in series with
necessary to maintain a prescribed air ffuel ratio the fuel injectors and is positioned downstream from
throughout the engine operational range. The them. Excess fuel supplied by the fuel pump, but not
powertrain control module then sends a command to required by the engine (6007), passes through the fuel
the fuel injectors to meter the appropriate quantity of pressure regulator and returns to the fuel tank through
fuel. a fuel and vapor return tube.
The powertrain control module also determines and
compensates for the age of the vehicle and its
compensate for changes in altitude (from sea level to Air Ind.uction System
mountains). The air induction system supplies filtered air to the
The SFI system can be subdivided into four distinct engine (6007) to mix with the fuel for combustion
categories: purposes. The air induction system consists of an
engine air cleaner hot air tube (9652), engine air
• Fuel delivery cleaner (ACL)(9600) with air cleaner element (ACL
• Air induction element)(9601), air cleaner outlet tube (98659), mass
air flow sensor (MAF sensor)( 128579), (on SFI units)
• Sensors throttle body (9E926), and intake manifold (9424). For
• Powertrain control module more information on the air induction system, refer to
The fuel delivery sub-system contains a high-pressure, Section 03-12.
in-tank fuel pump (9350). It delivers fuel from the fuel
tank (9002) through a 20 micron fuel filter (9155) to a
fuel injection supply manifold (90280).
The fuel injection supply manifold incorporates
electrically actuated fuel injectors directly above each
of the engine's four intake ports. The fuel injectors,
when energized, spray a metered quantity of fuel into
the intake air stream.

ALL RIGHTS RESERVED
4.9L Multiport Fuel Injection Engine
-.
FRONT OF ENGINE
V5838-G

ALL RIGHTS RESERVED
Part Part
1 9424 Intake Manifold (Upper) 5 90280 Fuel Injection Supply
2 9F483 EGR External Pressure Valve Manifold
3 90930 Fuel Charging Wiring 6 9424 Intake Manifold (Lower)
4 9E926 Throttle Body 7 9A474 Intake Manifold Vacuum
(Continued)
A constant fuel pressure drop is maintained across the • Air entering the engine is monitored by mass airflow,
fuel injectors by a fuel pressure regulator (9C968). pressure and temperature sensors.
The fuel pressure regulator is connected in series with • The outputs of the electronic engine control sensors
the fuel injectors and is positioned downstream from are processed by the powertrain control module.
them. Excess fuel supplied by the pump, but not
required by the engine, passes through the fuel • The powertrain control module determines the
pressure regulator and returns to the fuel tank (9002) needed fuel injector pulse width and outputs a
through a fuel return line. command to the fuel injectors to meter the exact
quantity of fuel.
Fuel Injection Timing - MFI Engines

Throttle Body
The fuel injectors are energized in two sets of three,
1-3-5 in one set and 2-4-6 in the other, with one set The throttle body (9E926) controls airflow to the
energized every crankshaft revolution. The period of engine through a double butterfly-type valve. The
time that the fuel injectors are energized (injector "on throttle position is controlled by multiple-link,
time" or pulse width) is controlled by the powertrain progressive opening, throttle linkage. The body is a
control module (PCM)( 12A650). Input from various single-piece die casting made of aluminum. It has a
engine sensors is used to compute the required fuel dual bore with an air bypass channel around the
flow rate necessary to maintain a prescribed air ffuel throttle plate. This bypass channel controls both cold
ratio for the given engine operation. The computer and warm engine idle control as regulated by an idle air
determines the needed injector pulse width and control valve (lAC valve)(9F715) mounted directly to
outputs a command to the injector to meter the exact the throttle body. The valve assembly is an
quantity of fuel. electro-mechanical device controlled by the
powertrain control module (PCM)(12A650).lt
incorporates a linear actuator which positions a
variable area metering valve.
Fuel Injection Timing - SFI Engines Other features of the throttle body include:
For fuel injection timing: 1. A preset stop to locate the WOT position.
• Each fuel injector is energized once every other 2. A throttle body-mounted throttle position sensor
crankshaft revolution in sequence with engine firing (TP sensor)(9B989).
order. 3. Two canister purge ports for evaporative
• The period of time that the fuel injectors are emission control.
energized (injector "on time" or pulse width) is
controlled by the vehicle's powertrain control
module (PCM)( 12A650).

ALL RIGHTS RESERVED
4. A Throttle Return Center (TRC) screw which sets

the closed position of the throttle plate. Do not
adjust or tamper with the TRC screw unless
instructed to do so by the Powertrain
Control/Emissions Diagnosis Manual. 1. If the
TRC screw is advanced too far, too much air will
be allowed at idle making it impossible for the
PCM to properly control idle speed and mixture
through the injectors and idle air control valve. If
backed-off too much, the throttle plate will stick.
5. A sealant which is applied to the down stream
side of the throttle plate and bore area to reduce
plate-to-bore leakage. This sealant makes the
throttle body tolerant of sludge accumulation and
should not be removed or cleaned.
THROTI1.E BODY
9E926
THROTTLE
PLATE
SET
SCREW
THROTTLE
POSITION
SENSOR
98989 CANISTER
PURGE Part
PORTS Item Number Description
1 9424 Intake Manifold, Upper
Gasket
3 12A697 Intake Air Temperature
Intake Manifold Sensor
The intake manifold (9424) is a two-piece (upper and 4 390715 Stud (7 Req'd.)
5/16-18 x 2.505
lower) aluminum casting. Runner lengths are tuned to
optimize engine torque and power output. The intake 5 9424 Intake Manifold
manifold provides mounting flanges for the throttle 6 390659-S 100 PCV Connector
body (9E926), fuel injection supply manifold (90280) 7 9A474 Intake Manifold Vacuum
and accelerator control bracketry and the EGR valve Outlet Fitting and Cap
and supply tube. Vacuum taps are provided to support A - Tighten to 16-24 N·m
various engine accessories. Pockets for the fuel (12-18 Lb-Ft)
injectors are machined to prevent both air and fuel
leakage. The pockets in which the fuel injectors are
mounted are placed to direct the injector fuel spray
immediately in front of each engine intake valve
(6507).
1 Can be purchased as a separate item


ALL RIGHTS RESERVED
03·048·6 Fuel Charging and Controls, 4.9L 03·048·6
Fuel Injectors
Part
The fuel injectors are electro-mechanical devices Item Number Description
which both meter and atomize fuel delivered to the
engine. The fuel injectors are mounted in the lower 6 - Lower Intake Manifold
O-Ring (Part of 9F593)
intake manifold (9424) and are positioned so that their
tips are directing fuel just before the engine intake 7 - End Cap
valves (6507). The valve body consists of a (Part of 9F593)
solenoid-actuated valve assembly, therefore, fuel flow 8 - Stainless Steel Valve Body
to the engine is regulated only by how long the (Part of 9F593)
solenoid is energized. An electrical signal from the 9 - Stainless Steel Needle
powertrain control module (PCM)( 12A650) activates (Part of 9F593)
the solenoid, causing the needle to move inward, off 10 - Electrical Connector
(Part of 9F593)
the seat, allowing the fuel to flow through the orifice.
Atomization of the fuel is obtained by
director / metering plate at the point where the fuel
separates.
The fuel injection supply manifold (90280) delivers
high-pressure fuel from the vehicle fuel supply line to
the six fuel injectors. The assembly consists of a
preformed tube for fuel supply and one for fuel return.
The fuel injection supply manifold has six injector
connectors, a mounting flange for the fuel pressure
regulator (9C968), and mounting attachments which
locate the fuel manifold assembly and provide fuel
injector retention. The fuel injection supply manifold
also is equipped with a fuel pressure relief valve
(9H321) on the fuel supply tube.
V10024-A
Part
A19017-B 1 - Fuel Supply Link Connection
(Part of 90280)
Part 2 - Fuel Return Line Connection
Item Number Description (Part of 90280)
3 - Injector Connector
1 - Supply Manifold O-Ring (Part of 90280)
(Part of 9F593)
2 - Integral Filter
5 90280 Fuel Injection Supply
(Part of 9F593)
Manifold
3 - Coil (Part of 9F593)
6 9H323 Fuel Pressure Relief Valve
4 - Armature (Part of 9F593) Cap
5 - Washer (Part of 9F593) 7 9H321 Fuel Pressure Relief Valve
(Continued)

ALL RIGHTS RESERVED
Fuel Pressure Regulator Fuel Pressure Relief Valve

The fuel pressure regulator (9C968) is attached to the The fuel pressure relief valve (9H321) is used to
fuel injection supply manifold (90280) downstream of relieve fuel pressure from the fuel system. The fuel
the fuel injectors. It regulates the fuel pressure pressure relief valve is located on the fuel injection
supplied to the fuel injectors. The fuel pressure supply manifold (90280). Refer to fuel system
regulator is a diaphragm-operated relief valve in which pressure relief procedures in this section.
one side of the diaphragm senses fuel pressure and
the other side is subjected to intake manifold vacuum.
The nominal fuel pressure is established by a spring
preload applied to the diaphragm. Balancing one side Fuel Charging Wiring
of the diaphragm with manifold pressure maintains a
constant fuel pressure drop across the fuel injectors. The fuel charging wiring (90930) connects the engine
Fuel, in excess of that used by the engine, is bypassed control sensor wiring (12A581) to each fuel injector
through the fuel pressure regulator and returns to the and other electronic engine controls such as throttle
fuel tank (9002). . position sensor (TP sensor)(9B989) and idle air
control valve (lAC valve)(9F715). The fuel charging
wiring receives fuel injector nozzle tip signals from the
powertrain control module (PCM)( 12A650) and
transfers the signals to the fuel injectors. The signals
from the powertrain control module determine the fuel
injection sequence and duration each fuel injector will
stay open to allow fuel into the combustion chambers.
Inertia Fuel Shutoff Switch
The inertia fuel shutoff switch (IFS switch)(9341) is
used in conjunction with an electric fuel pump (9350).
The purpose of the inertia fuel shutoff switch is to shut
off the fuel pump in the event of a collision. It consists
of a steel ball held in place by a magnet. When a sharp
impact occurs, the ball breaks loose from the magnet,
rolls up a ramp and strikes a target plate which opens
shutoff switch is open, it must be manually reset
before the vehicle can be restarted.
The inertia fuel shutoff switch is located behind the
right cowl side trim panel (02344) in the passenger
compartment.
V7787·C
Part
Tube (Part of 9H321 )
2 - Ball Seat (Part of 9H321)
3 - Spring (Part of 9H321)
4 - Upper Housing
(Part of 9H321)
5 - Diaphragm (Part of 9H321)
6 - Lower Housing
(Part of 9H321)
7 - Fuel Outlet Tube (Return)
(Part of 9H321)
8 - Fuel Inlet Tube (Supply) CUTAWAY VIEW EXTERNAL VIEW
(Part of 9H321)
9 - O-Ring Groove V9978-A
(Part of 9H321)
10 - Mounting Plate Part
(Part of 9H321)
(Part of 9H321) 1 9341 Inertia Fuel Shutoff Switch
12 - Spring Seat (Part of 9H321) 2 - Target Plate (Part of 9341)
(Continued)

ALL RIGHTS RESERVED
The fuel charging assembly consists of the throttle

Part body (9E926), and the upper and lower intake
Item Number Description manifolds (9424). Prior to service or removal of the
4 - Magnet (Part of 9341) fuel charging assembly, the following steps must be
5 - Switch Terminals taken:
(Part of 9341) 1. Disconnect battery ground cable (14301) and
6 - Electrical Contacts secure it out of the way.
(Part of 9341)
2. Remove air cleaner outlet tube (98659) from air
7 - Reset Button - Position
cleaner to throttle body.
with Switch Open - Fuel
Pump Off (Part of 9341) 3. Remove fuel tank filler cap (9030) to relieve tank
8 - Reset Button - Position pressure.
with Switch Closed - Fuel
Pump On (Part of 9341) 4. Remove fuel pressure relief valve cap (9H323).
5. Install Multiport Fuel Injection Fuel Pressure
Fuel Pump, Relay Gauge (EFI / CFI) Fuel Pressure Gauge
The fuel pump relay supplies power to the fuel pump T80l-9974-8 on fuel pressure relief valve
when the powertrain control module grounds the relay (9H321) and relieve fuel pressure.
during START and engine RUNNING conditions. It is Post-Service Procedures
located in the power network box in the engine
compartment. After the service is complete and the fuel charging
assembly is installed onto engine, the following steps
must be taken:
DIAGNOSIS AND TESTING 1. Install air cleaner outlet tube to throttle body.
2. Install the fuel tank filler cap.
Fuel Charging and Controls 3. Connect battery ground cable.
Refer to the Powertrain Control/Emissions Diagnosis 4. NOTE: Check all connections at fuel injection
2
Manual for fuel charging and controls diagnosis and supply manifolds (90280), push-connect fittings,
testing of fuel charging and controls components. fuel injectors, etc.
CAUTION: The fuel system is normally
Turn ignition switch (11572) on and off several
Fuel Injectors times without starting engine (6007) to pressurize
Testing the fuel system. Check for fuel leaks at fuel
pressure regulator (9C968), fuel injectors and
Test fuel injectors using Rotunda Fuel Injector fuel connect fittings.
Tester / Cleaner 113-00001 or equivalent. Follow tool
manufacturer's operating instructions. 5. Start engine and warm to operating temperature.
Check for coolant leak if coolant was removed.
REMOVAL AND INSTALLATION Refer to Powertrain Control/Emissions Diagnosis
2
Preservice Procedures

Multiport Fuel Injection Fuel Pressure T80L-9974-B
Gauge (EFI/ CFI Fuel Pressure Gauge)


ALL RIGHTS RESERVED


together by a garter spring inside a circular cage.
When the coupling is connected together, the flared
end of the female fitting slips behind the garter spring
inside the cage of the male fitting. The garter spring
and cage then prevent the flared end of the female
fitting from pulling out of the cage. As a redundant
locking feature, a horseshoe shaped retaining clip is
incorporated to improve the retaining reliability of the
spring lock coupling.
®
MALE CUPITETHER ASS'(

FITTING
©
SPRING-LOCK
COUPliNG
Removal
1. Release fuel system pressure. Refer to
Preservice Procedures in this section.
2. Remove retaining clip from spring lock coupling @
by hand only. Do not use any sharp tool or V4803-D
screwdriver as it may damage the spring lock
coupling. Installation
3. Twist fitting to free it from any adhesion at the 1. Make sure the garter spring is in cage of male
O-ring seals. fitting. If garter spring is missing, install a new
4. Using Spring Lock Coupling Disconnect Tool spring by pushing it into cage opening. If garter
T81 P-18623-G 1 (3/8 inch) or T81 P-18623-G2 spring is damaged, remove it from cage with a
(112 inch), disconnect fuel hoses at the fuel rail small wire hook (do not use a screwdriver) and
supply tube and fuel rail return tube. install a new spring.
a. Fit tool to coupling so tool can enter cage to 2. Clean all dirt or foreign material from both pieces
release garter spring. of coupling.
b. Push the tool into the cage opening to release 3. WARNING: USE ONLY THE SPECIFIED
female fitting from garter spring. O-RINGS AS THEY ARE MADE OF A SPECIAL
MATERIAL. THE USE OF ANY O-RING OTHER
c. Pull the coupling male and female fittings THAN THE SPECIFIED O-RING MAY ALLOW
apart. THE CONNECTION TO LEAK
d. Remove the tool from the disconnected INTERMITTENTLY DURING VEHICLE
coupling. OPERATION.
Replace missing or damaged O-rings. Use only
O-rings listed in Spring Lock Coupling illustration.
4. Lubricate male fitting and O-rings and inside of
female fitting with clean engine oil
XO-10W30-QSP meeting Ford specification
ESE-M2C 153-E or equivalent.
garter spring snaps over flared end of female
fitting.

ALL RIGHTS RESERVED
03-048-10 Fuel Charging and Controls, 4.9L 03·048·10
6. Make sure coupling engagement by pulling on 6. Carefully separate throttle body and accelerator
fitting and visually checking to make sure garter cable bracket (9723) from upper intake manifold
spring is over flared end of female fitting. (9424).
7. NOTE: All vehicles require the large black clip to 7. Remove and discard throttle body gasket (TB
be installed on the supply side fuel line and the gasket)(9E936).
small gray clip to be installed on the return side
fuel line.
THROTILE
Position retaining clip over metal portion of spring BODY-9E926
lock coupling. Firmly push retaining clip onto NUT
spring lock coupling. Make sure horseshoe (4 REO'D)
portion of clip is over the coupling. Do not install .19-27 Nem
(14-20 LB-~
Throttle Body
Removal
1. Disconnect throttle position sensor (TP
sensor)(9B989) and idle air control valve (lAC
valve)(9F715) connectors.
2. CAUTION: When disconnecting accelerator
cable (9A758) from ball stud, use a
screwdriver or similar tool close to the ball
stud to pry off. Removing by hand may
damage the cable.
Remove the accelerator control splash shield
(9E766). Disconnect the accelerator cable,
3.
transmission kickdown cable, and speed control
actuator (9A825) cable.
Disconnect the secondary air injection pump (AIR
---
pump)(9A486) from the throttle body (9E926). V5852-E
4. Disconnect the main emission vacuum control
connector (9E498) from the throttle body.
Installation
1. NOTE: If scraping is necessary, be careful not to
5. Remove four throttle body nuts.
damage gasket surfaces of throttle body and
upper manifold assemblies, or allow material to
drop into intake manifold.
Make sure that both throttle body and intake
manifold gasket surfaces are clean.
2. Install a new throttle body gasket on the four
studs of the upper intake manifold.
3. Position the accelerator cable bracket onto the
throttle body.
4. Install throttle body to upper intake manifold.
5. Secure throttle body to upper intake manifold with
four retaining nuts. lighten to 19-27 N·m (14-20
Ib-ft).
NUT (4)

ALL RIGHTS RESERVED
6. Connect idle air control valve and throttle position 2. Remove two retaining screws.
sensor electrical connectors. 3. Remove throttle position sensor.
IDLE AIR
Installation
THROTTLE
CONTROL VALVE
POSITION 1. CAUTION: Slide rotary tangs into position
ELECTRICAL
CONNECTOR SENSOR over throttle shaft blade, then rotate throttle
98989 position sensor CLOCKWISE ONLY to
installed position. Failure to install the
throttle position sensor in this manner may
result in excessive idle speeds.
Position the throttle position sensor so that the
connector points opposite the air valve. Then,
rotate throttle position sensor clockwise to align
over mounting screw holes.
2. NOTE: When throttle position sensor is installed
V5842·F
on the throttle body (9E926), the connector will
point toward the throttle body inlet.
7. Connect the main emission vacuum control Secure throttle position sensor to throttle body
connector to the throttle body. with two retaining screws. Tighten to 2-3 N·m
8. Connect speed control actuator cable, (18-27 Ib-in).
transmission kickdown cable, and accelerator 3. Connect electrical connector to fuel charging
cable. Install accelerator control splash shield. wiring.
9. Connect the secondary air injection pump to the
main emission vacuum control connector.
Idle Air Control Valve Assembly

Removal
Throttle Position Sensor
1. Disconnect the idle air control valve assembly
Removal connector from the fuel charging wiring (90930)·.
1. Disconnect throttle position sensor (TP 2. Remove the two idle air control valve retaining
sensor)(98989) from fuel charging wiring bolts.
(90930).
BOLTS
(2 REQ'D)
SCREW V5853·C
-------- 2-3 N·m
(18.27 LB-IN) V9979-A

ALL RIGHTS RESERVED
3. Remove the idle air control valve (lAC Fuel Injector

valve)(9F715) and idle air control gasket (lAC
gasket)(9F670). Removal
1. Perform all Preservice Procedures as described
in this section.
described in Section 03-01 A.
from individual fuel injectors as required.
4. Remove fuel injection supply manifold (90280) as
ELECTRICAL
CONNECTOR
Installation
damage idle air control valve or throttle body
gasket surfaces, or drop material into throttle
body (9E926).
FUEL
Make sure that both throttle body and idle air INJECTOR
control valve gasket surfaces are clean. 9F593 V4809-C
2. Install idle air control gasket and idle air control
valve on throttle body. 5. Grasping injector body, pull up while gently
rocking fuel injector from side-to-side.
IDLE AIR
CONTROL VALVE
9F715
FUEL
INJECTOR
9F593
GASKET V5858-C
9F670
V4801-E
3. Install retaining screws. Tighten to 8-11 N·m

(71-971b-in).
4. Connect electrical connector to the idle air control
valve.

ALL RIGHTS RESERVED
03-04B-13 Fuel Charging and Controls, 4.9L 03-04B-13
6. Inspect injector O-rings (two per injector) for

O-RING
'SEALS
V10024-A
V5040-C Part
Installation 1 - Fuel Supply Link Connection
1. CAUTION: Never use silicone grease. It will (Part of 90280)
clog the fuel injectors. 2 - Fuel Return Line Connection
(Part of 90280)
Lubricate new O-rings with light grade oil10W-30 3 - Injector Connector
meeting Ford specification ESE-M2C 153-E or (Part of 90280)
equivalent and install two on each fuel injector. 4 9C968 Fuel Pressure Regulator
2. Install fuel injectors using a light, twisting, pushing 5 90280 Fuel Injection Supply
motion. Manifold
3. Install fuel injection supply manifold as described 6 9H323 Fuel Pressure Relief Valve
Cap
in this section.
injectors.
5. Install upper intake manifold as described in
Section 03-01 A. Perform all Post-Service Fuel Injection Supply Manifold
Procedures as described in this section.
Fuel Pressure Relief Valve Spring Lock Coupling Disconnect Tool T81 P-19623-G 1
Spring Lock Coupling Disconnect Tool T8l P-19623-G2
Removal
1. Remove the upper intake manifold (9424). Refer
Multiport Fuel Injection Fuel Pressure T80L-9974-B to Section 03-01 A.
Gauge (EFI leFI Pressure Gauge)
2. Disconnect fuel line retaining clips.
Removal 3. WARNING: RELIEVE FUEL SYSTEM
1. Remove fuel pressure relief valve cap (9H323) PRESSURE BEFORE DISCONNECTING
from fuel injection supply manifold (9D280). COUPLING.
2. Perform fuel charging system preservice Using Disconnect Tool D87L-9280-Aor -8 or
procedures in this section. equivalents, disconnect fuel hoses at the fuel rail
supply tube and fuel rail return tube.
3. Using an open-end wrench, remove fuel pressure
relief valve (9H321) from fuel injection supply a. Fit tool to coupling so tool can enter cage to
manifold. release garter spring.
b. Push the tool into the cage opening to release
Installation female fitting from garter spring.
1. Install fuel pressure relief valve. lighten fuel c. Pull the coupling male and female fittings
pressure relief valve to 6-10 N·m (53-89 Ib-in). apart.
Install and securely tighten fuel pressure relief
valve cap.
1995 F-150, F-250, F-350, Bronco, F-Super Duty P9wertrain, Drivetrain July 1994

ALL RIGHTS RESERVED

coupling. FUEL INJECTOR
ASSEMBLY-9F593
(6) PLACES
~
FRONT OF
LOWER INTAKE
ENGINE
© MANIFOLD-9424
V5855-G
Installation
1. Make sure injector caps are clean and free of
contamination.
2. Install the fuel injectors into the fuel injection
supply manifold first to avoid damage to the
O-rings.
@ V480;,-D
3. Secure the fuel injection supply manifold using the
three retaining bolts. lighten to 8-12 N·m (70-106
Ib-in).
4. Disconnect the vacuum line to the fuel pres$ure
regulator (9C968). 4. Attach the vacuum line to the fuel pressure
regulator.
5. Remove the strap surrounding the fuel injection
supply manifold (90280), fuel charging wiring 5. Secure the main vacuum harness and the fuel
(90930), and the main vacuum harness. charging wiring to the fuel injection supply
manifold with a strap positioned between the No.
6. Remove the three fuel injection supply manifold
5 and No.6 intake manifold runners.
retaining studs.
6. Connect the fuel inlet and outlet lines at the fuel
7. Remove fuel injection supply manifold.
injection supply manifold connections. Refer to
8. Grasp injector body and pull up while gently the following illustration.
rocking fuel injector from side-to-side, to remove
a. Check for missing or damaged garter spring.
fuel injector.
Remove damaged spring with small hooked
wire.
b. Install new spring if damaged or missing.
c. Clean fittings.
d. Install new O-rings.
e. Lubricate with clean engine oil.
f. Assemble fitting by pushing with a slight
twisting motion.
g. To make sure of coupling engagement,
visually check to be sure garter spring is over
flared end of female fitting.
7. Connect fuel line retaining clips.

ALL RIGHTS RESERVED
8. Install the upper intake manifold as described in

Section 03-01 A.
GARTER
SPRING
19E576
V10024-A
Part
1 - Fuel Supply Link Connection
(Part of 90280)
2 - Fuel Return Line Connection
(Part of 90280)
3 - Injector Connector
(Part of 90280)
5 90280 Fuel Injection Supply
V5908-D Manifold
Cap
Fuel Pressure Regulator 2. Remove vacuum line at fuel pressure regulator
(9C968).
3. Remove two Allen screws from fuel pressure
Description Tool Number regulator housing.
Multipart Fuel Injection Fuel Pressure T80L-9974-B 4. Remove fuel pressure regulator, gasket and
Gauge (EFI / eFI Pressure Gauge) O-rings. Discard gasket and inspect O-rings for
signs of cracks or deterioration.
Removal
damage fuel pressure regulator or fuel injection
supply manifold gasket surfaces. O-RINGS
Perform Fuel Charging System Preservice

Procedures in this section.
Vl0025-A
Installation
1. Make sure gasket surfaces of fuel pressure
regulator and fuel injection supply manifold
(90280) are clean.
1995 F-150, F-250, F-350, Bronco, F-Super Duty ~owertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
2. CAUTION: Never use silicone grease. It will 3. Remove strap attaching fuel charging wiring
clog the fuel Injectors. (90930) to fuel injection supply manifold
Lubricate fuel pressure regulator O-ring with light (90280).
oil 10W-30 meeting Ford specification 4. Disconnect fuel charging wiring at:
WSE-M2C903-A2 or equivalent.
• Engine Control Sensor Wiring (12A581)
3. Install O-ring and new fuel pressure regulator
gasket (9C977) on fuel pressure regulator. • Fuel Injectors
4. Install fuel injectors on fuel injection supply • Water Temperature Indicator Sender Unit
manifold. Tighten two Allen screws to 3-5 N·m (10884)
(27-441b-in). • EVAP System Connector
5. Install vacuum line at fuel pressure regulator. • Engine Coolant Temperature Sensor (ECT
6. Perform Post-Service Procedures as described in sensor)( 12A648)
this section. • Intake Air Temperature Sensor (IAT
sensor)( 12A697)
• Delta PFE Sensor (California)
Fuel Charging Wiring • Heated Oxygen Sensor (H02S)(9F472)
(California)
Removal and Installation 5. Remove fuel charging wiring from vehicle.
1. Perform Fuel Charging System Preservice 6. For installation, reverse removal steps.
Procedures in this section.
7. Check for sensor function by performing EEC Self
2. Disconnect battery ground cable (14301). Test. Refer to Powertrain Control/Emission
Remove upper intake manifold (9424) as outlined Diagnosis Manual.
3
in Section 03-01 A.


ALL RIGHTS RESERVED
Fuel Charging Wiring, 4.9L MFI and SFI
,.
VIEW A
FRONT OF
•
ENGINE
49 STATE
FRONT OF
•
ENGINE
STRAP ASSEMBLED
..
FRONT OF
ENGINE
CALIFORNIA
YIEWA
V9980-A
Part Part
1 90930 Fuel Charging Wiring - 9 9E527 Fuel Injector - Six Places
49-State 10 90280 Fuel Injection Supply
2 - Connector to Engine Control Manifold
Sensor Wiring 11 6N697 Strap
(Part of 90930) 12 - Connector to Water
3 - Connector to Fuel Injectors Temperature Sending Unit
-Six Places (Part of 90930)
(Part of 90930) 13 90930 Fuel Charging Wiring -
4 - Connector to EVAP System California
(Part of 90930) 14 - Connector to EGR Delta PFE
5 - Connector to Coolant Sensor (Part of 90930)
Temperature Sensor 15 - Connector to Heated Oxygen
(Part of 90930) Sensor (H02S) (Front
6 - Connector to Air Charge Exhaust Manifold)
Temperature Sensor (Part of 90930)
(Part of 90930) 16 - Connector to Heated Oxygen
7 12A648 Engine Coolant Temperature Sensor (H02S) (Rear
Sensor Exhaust Manifold)
8 12A697 Intake Air Temperature (Part of 90930)
Sensor
(Continued)

ALL RIGHTS RESERVED
Fuel Pump Relay 8. CAUTION: Do not start engines that have

airflow meters.
Start the actuator and then start the engine.
9. Spray Carburetor Tune-Up Cleaner
2. Open cover of power network box. D9AZ-19579-BA, meeting Ford specification
3. Remove fuel pump relay which is named in base ESR-M 14P9-A or equivalent, into the idle air
of box. control valve passage leading to the inlet of the
4. To install, reverse removal steps. valve for up to one minute. Do not spray for longer
than six continuous seconds on engines that have
airflow meters and are not running.
CLEANING AND INSPECTION 10. Stop the actuator and stop the engine if running.
11. Reinstall the air cleaner outlet tube.
Throttle Body 12. Start and run the engine for about one minute to
dry out the solvent residue.
NOTE: The throttle body (9E926) for this vehicle is a
sludge tolerant design and should not be cleaned. 13. Operate the actuator to make sure the solvent is
purged from the idle air control valve.
14. Disconnect the actuator from the idle air control
valve.
Idle Air Control Valve 15. Reattach the control signal lead to the idle air
Recommended Cleaning Procedure control valve.
1. CAUTION: This cleaning procedure may be 16. Check the engine for normal operation.
used with sludge tolerant bodies which are Alternate Cleaning Procedure
Identified with a yellow/black "attention"
label. No attempt should be made to clean NOTE: Method to be used only when the Rotunda Fuel
the throttle body bore/plate area by directly Injector Tester / Cleaner 113-00001 and Air Bypass
spraying or scrubbing. Do not run vehicles Valve Actuator 113-00009 or equivalent for the
with airflow meters during the cleaning recommended method are not available.
procedure. Remove the idle air control valve from the throttle
Plug the Rotunda Air Bypass Valve Actuator body. Remove the electrical solenoid assembly from
113-00009 or equivalent into the Rotunda Fuel the mechanical portion of the idle air control valve by
Injector Tester / Cleaner 113-00001 or removing the two screws, then sliding the mechanical
equivalent. portion away from the solenoid.
2. Remove the air cleaner outlet tube (9B659) to the CAUTION: Do not exceed three minutes soak
throttle body (9E926). time, and do not use choke cleaner as an internal
O-ring may begin to deteriorate.
3. Disconnect the idle air control valve signal lead.
Soak the mechanical portion in Carburetor Tune-Up
4. Attach the Rotunda Air Bypass Valve Actuator
Cleaner D9AZ-19579-BA meeting Ford specification
113-00009 or equivalent plug to the idle air
ESR-M 14P9-A or equivalent for two to three minutes
control valve (lAC valve)(9F715).
maximum.
5. CAUTION: Do not start engines (6007) that With the mechanical portion completely submerged,
have airflow meters. shake in all directions: up, down, right and left. Then
Start the actuator and then start the engine., push in on the rod that mates with the solenoid
6. Spray Carburetor Tune-Up Cleaner assembly, and again shake in all directions with the
D9AZ-19579-BA meeting Ford specification unit submerged and the rod held in as far as possible.
ESR-M 14P9-A or equivalent for about five Remove the unit from the cleaning fluid and dry out
seconds into the inlet passage while the actuator thoroughly using shop air.
is operating. Avoid direct spraying on throttle
plate / bore area.
7. Stop the engine and actuator. Let everything
soak for 15 minutes.
ALL RIGHTS RESERVED
ADJUSTMENTS SPECIAL SERVICE TOOLS/EQUIPMENT
Idle Speed SPECIAL SERVICE TOOLS REQUIRED

Refer to Powertrain Control/Emissions Diagnosis Tool Number/
4
Manual for the idle speed adjustment procedures. Description IIIu8tration
T80L-9974-B
SPECIFICATIONS Pressure Gauge (EFI / CFI Fuel
Pressure Test Gauge)
TORQUE SPECIFICATIONS
Description N·m Lb-Ft TIOL·1I7...
Lower Intake Manifold to Head 30-43 22-32

T81 P-19623-G2
EGRTube 34-47 25-35 Spring Lock Coupling
EGR Valve to Upper Intake 18-26 13-19 Disconnect Tool (1/2 inch)
Manifold
Upper Intake Manifold to Lower 16-24 12-18
Intake Manifold Bolts
TI1 P·1.23-02
Throttle Body to Upper Intake 16-24 12-18
Manifold T81 P-19623-G 1
Idle Air Control Valve to Throttle 8-11 71-97 Spring Lock Coupling
Body (Lb-In) Disconnect Tool (3/8 inch)
Throttle Position Sensor to 2-3 18-27
Throttle Body (Lb-In)
Fuel Pressure Regulator to Fuel 3-4 27-44
TI1p·11123-G1
Injection Supply Manifold (Lb-In)
Fuel Supply Manifold to Fuel
Charging Assembly
16-20
. 12-15
ROTUNDA EQUIPMENT
Coil Bracket to Block 16-24 12-18 Model De8crlptlon
Throttle Cable Bracket to Throttle 16-24 12-18 007-0041-B SUPER STAR II
Body
113-00001 Fuel Injector Tester / Cleaner
Support Bracket 30-43 22-32
113-00009 Air Bypass Valve Actuator
Thermactor Tube Retainer Nuts 11-16 8-12
007-00500 New Generation Star (NGS) Tester
Transmission Fill Tube Retainer 11-16 8-12
Nut
Fuel Supply Manifold-to-Lower 8-12 70-105
Intake Manifold Retainer Bolts (Lb-In)
Pressure ReHef Valve 6-10 53-88
(Lb-In)


ALL RIGHTS RESERVED
03-04C-1 Fuel Charging and Controls, 7.5L 03-04C-1
SECTION 03·04C Fuel Charging and Controls, 7.5L

VEHICLE APPLICATION •••••••••••••••.•••••••••••••..•.•••••.••••03-04C-1 REMOVAL AND INSTALLATION (Cont'd.)
DESCRIPTION AND OPERATION Fuel Pressure Relief ..••.•••••••••••••••.•.•..••.•••.••.•.•••03.o4C·7
Air Induction System •.•••••••••••••••••••••••••••••••••••••••••03-04C-3 Post·Servlce Procedures•••••••••.•••••••••••••.•••••.••••03-Q4C·7
Fuel Charging Wiring •••••••••••••••••••••••••••••••••••••••••••03.o4C-5 Fuel Charging Wiring ••••..••••••••••••.•••.•.•••..••.•••••.••03.o4C·12
Fuel Injection Supply Manifold •••••••••••••••••••••••••••••03-04C-4 Fuel Injection Supply Manifold •••.•••••••••.•••..•...••••03·04C·10
Fuel Injection nmlng •••••••••••••••••••••••••••••••••••••••••••03·04C·2 Fuel Injector •••••••.••.•••.••••...••..••••....•..••.••••••••••.••.••03.o4C·9
Fuel Injectors ••••••••••••••••••••.••••••••••••••••••••••••••••••••.03-04C·4 Fuel Pressure Regulator .••••..••.••••••.•••.•••..••.......•03·04C·12
Fuel Pressure Regulator ••••••••••••••••••••••••••••••••••••••03.o4C·5 Fuel Pump Relay •.•••••••••••••••••••.••.•••.•.•.•••••••••.••.••O3·04C·12
Fuel Pressure Relief Valve •••••.•••••••••••••••••••••••••••.•03·04C·5 Spring Lock Coupling ....•.....•..••.••••••••.•....•.•..•••••••03·04C·7
. Fuel Pump Relay ••••••••••••••••••••.•••••••••••••••••••.•••••••••03·04C-6 Throttle Body •••••..••••••••••••••••.•••••...•••••••••••••••••••...03.o4C·8
Fuel System ••••••••••••••••••••••••••••••••••••.•••••••••••••••••••03.o4C·1 CLEANING AND INSPECTION
Inertia Fuel Shutoff (IFS) Swltch••••••••••••••••.••••••••••03.o4C-6 Fuel Injector •••.•••...•.•••••.•••..••........•..•••••••••••.•.•.•.03.o4C-13
Intake Manifold ••••••••••••••••••••••••••••..•••••••••••••••••••••03-04C·3 Throttle Body •.••••.••.••..•••••••••••.•••.••••••••••..••••••••••03·04C·12
Throttle Body •••••••••••••••••••••••••••••••••••...••••••••••••••••03·04C·3 ADJUSTMENTS
DIAGNOSIS AND TESTING Idle Speed ••••.•••••.....••.••.•••...•........••.••••.••••••••.••••03·04C·13
Fuel Charging and Controls ••••••••••••••.••••••••••••••••••03·04C·6 SPECIFICATIONS•.••••••••••••••••.•••••••••••••.••••..••.••••••••03.04C-13
REMOVAL AND INSTALLATION SPECIAL SERVICE TOOLS/EQUIPMENT..••••••••••••••03·04C·13
Fuel Charging System ••••.••••••••••••••••••••••••••••••••••••03·04C·7
VEHICLE APPLICATION
F-250-350 and F-Super Duty Vehicles Equipped with
7.5L MFI V-8 Engines
Fuel System The fuel delivery subsystem consists of a

The multiport fuel injection system (MFI) is classified high-pressure in-tank mounted fuel pump, and a fuel
as a multi-point, pulse time, speed density control fuel filter f reservoir delivering fuel from the fuel tank (9002)
injection system. Fuel is metered into each intake port through a chassis-mounted 20 micron fuel filter to a
in a sequential firing order. Fuel injectors (9F593) fuel injection supply manifold (9F792).
pulse to follow engine firing order in accordance with The fuel injection supply manifold incorporates
engine demand through injectors mounted on a tuned electrically-actuated fuel injectors directly above each
intake manifold. of the engine's eight intake ports. The fuel injectors,
A powertrain control module (PCM)( 12A650) accepts when energized, spray a metered quantity of fuel into
input from various engine sensors to compute the the intake air stream.
required fuel flow rate necessary to maintain a A constant fuel pressure drop is maintained across the
prescribed air ffuel ratio throughout the entire engine fuel injectors by a fuel pressure regulator (9C968).
operational range. The computer then outputs a The fuel pressure regulator is connected in series with
command to the fuel injectors to meter the appropriate the fuel injectors and is positioned downstream from
quantity of fuel. them. Excess fuel supplied by the pump, but not
The powertrain control module also determines and required by the engine, passes through the regulator
compensates for the age of the vehicle and its reservoir input and returns to the fuel tank through a
uniqueness. The system will automatically sense and fuel return line.
compensate for changes in altitude (Le., from sea level
to mountains) and also permits push-starting the
vehicle should it become necessary (manual
transmission only).

ALL RIGHTS RESERVED
7.5L Multlport Fuel Injection Engine
V5880-E
Part
1 90930 Fuel Charging Wiring
3 9F792 Fuel Injection Supply
Manifold
Part
4 9424 Intake Manifold, Lower
2 9424 Intake Manifold, Upper
4 9F792 Fuel Injection Supply Fuel Injection Timing
Manifold
5 9F715 Idle Air Control Valve Each fuel injector (9F593) is energized once every
other crankshaft revolution in sequence with engine
firing order. The period of time that the fuel injectors
7 9F593 Fuel Injectors are energized (injector "on time" or pulse width) is
controlled by the vehicle's powertrain control module
(PCM)( 12A650). Air entering the engine is monitored
by flow, pressure and temperature sensors. The
outputs of these electronic engine control sensors are
processed by the powertrain control module. The
powertrain control module determines the needed fuel
injector pulse width and outputs a command to the fuel
injector to meter the exact quantity of fuel.

ALL RIGHTS RESERVED
Air Induction System Intake Manifold

The air induction system supplies filtered air to the The intake manifold (9424) is a two-piece (upper and
engine to mix with the fuel for combustion purposes. lower) aluminum casting. Runner lengths are tuned to
The air induction system consists of an engine air optimize engine torque and power output. The intake
cleaner intake tube (9A624), engine air cleaner manifold provides mounting flanges for the throttle
assembly with filter, air cleaner outlet tube (98659), body (9E926), fuel injection supply manifold (9F792)
mass air flow sensor (MAF sensor)( 128579), throttle and accelerator control bracketry, idle air control
body (9E926) and intake plenum. valve (lAC valve)(9F715) and the EGR external
pressure valve (9F483). Vacuum taps are provided to
support various engine accessories. Pockets for the
fuel injectors (9F593) are machined to prevent both air
Throttle Body and fuel leakage. The pockets in which the fuel
injectors are mounted are placed to direct the injector
The throttle body (9E926) controls airflow to the fuel spray immediately in front of each engine intake
engine through a double butterfly-type valve. The valve (6507).
throttle position is controlled by a four-bar link,
progressive opening, throttle linkage. The throttle
body is a single-piece die casting made of aluminum.
Other features of the throttle body include:
1. A preset stop to locate the WOT position.
(TP sensor)(98989).
3. Sludge-resistant coating applied to the
downstream side of the throttle plate and bore
area to reduce the plate-to-bore leakage. The
coating should NOT be removed or cleaned.
4. The plate position at idle is set by the throttle
return control (TRC) screw contacting the throttle
lever arm. Do not adjust / tamper with this screw
unless instructed to do so by the Powertrain
Control/Emissions Diagnosis Manual. 1
THROnLE BODY
9E926
THROTILE LOWER INTAKE

POSITION MANIFOLD
SENSOR" 9424
98989 V5881·E
V58&4·E


ALL RIGHTS RESERVED
Fuel Injectors
Part
The fuel injector (9F593) is a solenoid-operated valve Item Number Description
that meters fuel flow to the engine. The fuel injector is
opened and closed a constant number of times per 8 - Stainless Steel Valve Body
crankshaft revolution. The amount of fuel is controlled (Part of 9F593)
by the length of time the fuel injector is held open. The 9 - Stainless Steel Needle
fuel injector is normally closed and is operated by a (Pintle) (Part of 9F593)
signal from the powertrain control module 10 - Electrical Connector
(PCM)(12A650). (Part of 9F593)

high-pressure fuel from the vehicle fuel supply line to
the eight fuel injectors (9F593). The fuel injection
supply manifold consists of two banks of tubular fuel
rails connected by two permanent crossover
flange to the fuel pressure regulator (9C96a) and
mounting attachments which locate the fuel injection
supply manifold and provide fuel injector retention. The
fuel inlet and return have push-connect fittings. The
unit is serviced as an assembly only.
A19017-A
Part
Item Number Description V5865-E
1 - Supply Manifold Q-Ring
(Part of 9F593) Part
2 - Integral Filter Item Number Description
(Part of 9F593)
1 - Fuel Return (Part of 9F792)
3 - Coil (Part of 9F593)
4 - Armature (Part of 9F593)
5 - Washer (Part of 9F593)
4 - Injector Pockets
6 9229 Q-Ring Seal, Lower Intake (Part of 9F792)
Manifold - Fuel Inlet (Part of 9F792)
5
7 - End Cap
(Part of 9F593)
(Continued)

ALL RIGHTS RESERVED

Part
The fuel pressure regulator (9C968) is attached to the Number Description
Item
fuel injection supply manifold (9F792) downstream of
the fuel injectors (9F593). It regulates the fuel 6 - Lower Housing
pressure supplied to the fuel injectors. The fuel (Part of 9C968)
pressure regulator is a diaphragm-operated relief 7 - Fuel Outlet Tube (Return)
valve in which one side of the diaphragm senses fuel (Part of 9C968)
pressure and the other side is subjected to intake 8 - Fuel Inlet Tube (Supply)
manifold vacuum. The nominal fuel pressure is (Part of 9C968)
established by a spring preload applied to the 9 - O-Ring Groove
diaphragm. Balancing one side of the diaphragm with (Part of 9C968)
manifold pressure maintains a constant fuel pressure 10 - Mounting Plate
drop across the fuel injectors. Fuel in excess of that (Part of 9C968)
used by the engine is bypassed through the fuel 11 - Fuel Filter Spring
pressure regulator and returns to the fuel tank (9002). (Part of 9C968)
12 - Spring Seat (Part of 9C968)
13 - Valve Assembly
(Part of 9C968)

The fuel pressure relief valve (9H321) is used to
relieve fuel pressure from the fuel system. The fuel
pressure relief valve is located on the fuel injection
supply manifold (9F792).

electronic engine controls such as throttle position
Part (lAC valve)(9F715). The fuel charging wiring receives
Item Number Description fuel injector signals from the powertrain control module
(PCM)( 12A650) and transfers the signals to the
1 - Engine Vacuum Reference throttle position sensors. The signals from the
Tube (Part of 9C968)
powertrain control module determine the fuel injection
2 - Ball Seat (Part of 9C968) sequence and duration each throttle position sensor
3 - Spring (Part of 9C968) will stay open to allow fuel into the combustion
4 - Upper Housing chambers.
(Part of 9C968)
5 - Diaphragm (Part of 9C968)
(Continued)

ALL RIGHTS RESERVED

Part
The inertia fuel shutoff switch (IFS switch)(934 1) is
used in conjunction with an electric fuel pump (9350).
The purpose of the inertia fuel shutoff switch is to shut 3 - Magnet (Part of 9341)
off the fuel pump in the event of a collision. It consists 4 - Switch Terminals
of a steel ball held in place by a magnet. When a sharp (Part of9341)
impact occurs, the ball breaks loose from the magnet, 5 - Electrical Contacts
rolls up a ramp and strikes a target plate which opens (Part of 9341)
before restarting the vehicle. Fuel Pump Relay
(9350) when the powertrain control module
(PCM)( 12A650) grounds the relay during START and
engine RUNNING conditions.
Fuel Charging and Controls

2
Manual.
CIJTAWAY VIEW
EXTERNAL VIEW
V9333-A
Part
1 - Target Plate (Part of 9341)
(Continued)


ALL RIGHTS RESERVED
Fuel Charging System 3. NOTE: When the battery has been disconnected
Pre-Service Procedures symptoms may occur while the powertrain
The fuel charging assembly consists of the throttle control module (PCM)( 12A650) relearns its
body (9E926), and the upper and lower intake adaptive strategy. The vehicle may need to be
manifolds (9424). Prior to service or removal of the driven 10 miles or more to relearn the strategy.
fuel charging assembly, the following steps must be Connect battery ground cable.
taken:
4. NOTE: Check all connections at fuel rails,
1. Disconnect battery ground cable battery lead and push-connect fittings, fuel injectors, etc.
secure it out of the way. Remove the fuel supply
manifold shield (9J314). CAUTION: The fuel system is normally
2. Disconnect air cleaner outlet tube (98659) from
throttle body. Turn ignition switch (11572) on and off several
times without starting engine to pressurize the
3. Remove fuel tank filler cap (9030) to relieve tank fuel system. Check for fuel leaks at fuel pressure
pressure. regulator (9C96B), fuel injectors (9F593) and fuel
4. Relieve pressure from fuel system at fuel connect fittings.
pressure relief valve (9H321) (Schrader) on fuel 5. Start engine and warm to operating temperature.
injection supply manifold (9F792) as described in Check for coolant leak if coolant was removed.
the following procedure.
Fuel Pressure Relief Refer to Powertrain Control/Emissions Diagnosis
3
WARNING: FUEL SUPPLY TUBES WILL REMAIN Manual. Recheck for fuel leaks.
PRESSURIZED FOR LONG PERIODS OF TIME
AFTER ENGINE SHUTDOWN. THIS PRESSURE
MUST BE RELIEVED BEFORE SERVICING OF THE
FUEL SYSTEM IS BEGUN. A VALVE IS PROVIDED Spring Lock Coupling
ON THE FUEL INJECTION SUPPLY MANIFOLD FOR
THIS PURPOSE. SPECIAL SERVICE TOOL(S) REQUIRED
SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number

Multipart Fuel Injection (MFI) Fuel T80L-9974-B
Pressure Gauge (EFI / CFI Fuel Pressure The spring lock coupling is a fuel line coupling held
Gauge together by a garter spring inside a circular cage.
When the coupling is connected, the flared end of the
1. Remove the protective cap from the fuel pressure female fitting slips behind the garter spring inside the
relief valve. cage of the male fitting. The garter spring and cage
2. Connect Multiport Fuel Injection (MFI) Fuel then prevent the flared end of the female fitting from
Pressure Gauge (EFI/CFI Fuel Pressure Gauge) pulling out of the cage. As a redundant locking feature,
T80L-9974-8 to the fuel pressure relief valve on a horseshoe shaped retaining clip is incorporated to
the fuel injection supply manifold. improve the retaining reliability of the spring lock
coupling.
3. Place end of the adapter hose in a suitable
container.
4. Open the manual valve on the Multiport Fuel MALE CUPITETHER ASS'(
FITTING
Injection (MFI) Fuel Pressure Gauge (EFI / CFI
Fuel Pressure Gauge) TBOl-9974-8 to relieve
fuel system pressure.
5. Close the manual valve and disconnect the tool
from the fuel pressure relief valve. Remove
container.
SPRING-LOCK
6. Install the protective cap on the fuel pressure COUPLING V7328-A
relief valve.
Removal
Post-Service Procedures 1. Relieve fuel system pressure as described in this
After the service is complete and the fuel charging section.
assembly is installed onto engine, the following steps
2. Remove retaining clip from spring lock coupling
must be taken:
by hand only. Do not use any sharp tool or
1. Install air cleaner outlet tube to throttle body. screwdriver as it may damage the spring lock
2. Install the fuel tank filler cap. coupling.


ALL RIGHTS RESERVED
3. Twist fitting to free it from any adhesion at the Installation

O-ring seals. 1. WARNING: USE ONLY THE SPECIFIED
4. Using Spring Lock Coupling Disconnect Tool O-RINGS AS THEY ARE MADE OF A SPECIAL
T81 P-19623-G 1 (3/8 Inch) or T81-19623-G2 MATERIAL. THE USE OF ANY O-RING OTHER
(1 /2 Inch), disconnect fuel hoses at the fuel rail THAN THE SPECIFIED O-RING MAY ALLOW
supply tube and fuel rail return tube. THE CONNECTION TO LEAK
a. Fit tool to coupling so tool can enter cage to INTERMITTENTLY DURING VEHICLE
release garter spring. OPERATION.
b. Push the tool into the cage opening to release Make sure the garter spring is in cage of male
female fitting from garter spring. fitting. If garter spring is missing, install a new
spring by pushing it into cage opening. If garter
c. Pull the coupling male and female fittings spring is damaged, remove it from cage with a
apart. small wire hook (do not use a screwdriver) and
d. Remove the tool from the disconnected install a new spring.
coupling. 2. Clean all dirt or foreign material from both pieces
of coupling.
3. Replace missing or damaged O-rings.
4. Lubricate male fitting and O-rings and inside of
female fitting with clean engine oil
XO-10W30-QSP or equivalent meeting Ford
specification ESE-M2C 153-E.
fitting.
® 6. Make sure of coupling engagement by pulling on
fitting and visually checking to make sure garter
spring is over flared end of female fitting.
7. NOTE: All vehicles require the large black clip to
be installed on the supply side fuel line and the
small gray clip to be installed on the return side
® fuel line.
Position retaining clip over metal portion of spring
spring lock coupling. Make sure horseshoe
portion of clip is over the coupling. Do not install
©
Throttle Body
Removal
1. Remove air inlet hoses.
2. Disconnect throttle linkage at throttle ball and
automatic transmission linkage, if equipped, from
throttle body (9E926). Remove two bolts
securing bracket to intake manifold (9424) and
@ V4803-0 position bracket with cable(s) out of the way.

ALL RIGHTS RESERVED
3. Disconnect electrical connector at throttle Installation

position sensor (TP sensor)(9B989). 1. NOTE: If scraping is necessary, be careful not to
damage gasket surfaces of throttle body and
THROTILE upper intake manifold, or allow material to drop
POSITION SENSOR into intake manifold.
98989 EGR EXTERNAL
PRESSURE
Install throttle body gasket (TB gasket)(9E936)
VALVE between upper intake manifold and throttle body.
9F483 Make sure throttle body gasket stays in place if
alignment studs are not used.
2. Install throttle body to upper intake manifold.
3. Secure throttle body to upper intake manifold with
four retaining bolts. lighten to 15-24 N·m (12-18
Ib-ft).
V5869-G
4. Remove four throttle body bolts.

5. Carefully separate throttle body from upper
intake manifold.
4. Connect throttle position sensor electrical

connectors.
Fuellnjeclor
Removal
1. Perform pre-service procedures as described in
this section.
2. Relieve fuel system pressure as described in this
section.
3. Remove upper intake manifold (9424). Refer to
V5871-F Section 03-01C.
4. Remove fuel injection supply manifold (9F792) as
from individual fuel injectors (9F593) as required.

ALL RIGHTS RESERVED
6. Grasping injector body, pull up while gently

rocking fuel injector from side to side.
O-RING
. SEALS
VS040-C
Installation
1. NOTE: Never use silicone lubricant. It will clog the
fuel injectors.
Lubricate new a-rings with light grade oil 10W-30
ESE-M2C 153-E and install two on each fuel
injector.
2. Install fuel injectors. Use a light, twisting, pushing
motion to install them.
in this section.
injectors.
5. Install upper intake manifold. Refer to Section
03-01C.
in this section.
Part SPECIAL SERVICE TOOL(S) REQUIRED

Item Number Description Description Tool Number
1 90930 Fuel Charging Wiring Spring Lock Coupling Disconnect Tool T81 P-19623-G 1
2 9F792 Fuel Injection Supply Spring Lock Coupling Disconnect Tool T81 P-19623·G2
Manifold
3 9E527 Fuel Injector Nozzle Tip Removal
1. Perform pre-service procedures as described in
5 56105-52 Bolt
this section.
(71-106 Lb-In) 2. Relieve fuel system pressure as described in this
section.
7. Inspect injector a-rings (two per injector) for 3. Remove upper intake manifold (9424). Refer to
signs of deterioration. Replace as required. Section 03-01C.
8. NOTE: End cap is not available as a separate 4. Remove fuelline-to-fuel supply manifold retainer
part. clips.
Inspect injector end cap and washer for signs of
deterioration. Replace complete fuel injector as
required. If end cap is missing, look for it in intake
manifold.

ALL RIGHTS RESERVED
5. Disconnect vacuum hose at fuel pressure

regulator (9C968).
FUEL RETURN
UNECLlP---.....,
N805526-S190
©
V7480-1A
6. WARNING: RELIEVE FUEL SYSTEM

PRESSURE BEFORE DISCONNECTING
COUPLING.
Using Spring Lock Coupling Disconnect Tool
T81 P-19623-G 1 (3/8 Inch) or T81 P-19623-G2
(1 /2 Inch), disconnect fuel hoses at the fuel rail @ V4803-0
7. Remove four fuel injection supply manifold
a. Fit tool to coupling so tool can enter cage to retaining bolts.
release garter spring.
8. Carefully disengage fuel injection supply manifold
b. Push the tool into the cage opening to release (9F792) from fuel injectors (9F593) and remove
female fitting from garter spring. fuel injection supply manifold.
c. Pull the coupling male and female fittings
Installation
apart.
1. Make sure injector caps are clean and free of
contamination.
coupling.
2. Place the fuel injection supply manifold over each
of the fuel injectors and seat fuel injectors into fuel
injection supply manifold. Make sure fuel injectors
are properly seated.
3. Secure fuel injection supply manifold using four
retaining bolts. Tighten to 8-12 N·m (71-106
Ib-in).
4. Connect fuel inlet and outlet lines at fuel injection
supply manifold connections. Push in to connect.
5. Install fuelline-to-fuel injection supply manifold
retaining clips.
6. Connect vacuum hose to fuel pressure regulator.
section.
in this section.

ALL RIGHTS RESERVED

Part
Removal Item Number Description
1. Perform all pre-service procedures as described 5 9F792 Fuel Injection Supply
in this section if removing fuel pressure regulator Manifold
(9C968) while fuel injection supply manifold
(9F792) is installed on engine. Installation
2. Relieve fuel system pressure as described in this 1. NOTE: Never use silicone grease. It will clog the
section. fuel injectors (9F593).
3. Remove vacuum line at fuel pressure regulator. Lubricate fuel pressure regulator O-rings with
4. Remove two socket head retaining screws from light oil 10W-30 or equivalent meeting Ford
fuel pressure regulator housing. specification ESE-M2C 153-E.
5. Remove fuel pressure regulator, return seal and 2. Make sure return seal surfaces of fuel pressure
O-rings. Discard return seal and O-rings. regulator and fuel injection supply manifold are
clean.
6. If scraping is necessary, be careful not to damage
fuel pressure regulator or fuel supply line seal 3. Install new O-rings and a new return seal on fuel
surfaces. pressure regulator.
4. Install fuel pressure regulator on fuel injection
supply manifold. Tighten two retaining screws to
3-5 N·m (27-42Ib-in).
5. Install vacuum line to fuel pressure regulator.
in this section.

1. Remove upper intake manifold (9424). Refer to
Section 03-01C.
2. Disconnect fuel charging wiring (90930) from fuel
injectors (9F593) and electronic engine controls.
3. Remove fuel charging wiring ground strap
control sensor wiring (12A581).
5. For installation, follow removal procedures in
reverse order. Verify all connections.
Fuel Pump Relay

Remove and Installation
1. Locate and remove malfunctioning fuel pump
relay by pulling it out of its cavity.
2. Replace fuel pump relay with one of the proper
amp rating for the circuit by pushing straight in
V5874-D until fuel pump relay seats itself fully in cavity.
Part
Item Number Description CLEANING AND INSPECTION
1 N807244 Return Seal
2 N807547 O-Ring
Throttle Body
3 N802353-S 101 Screws
4 9C968 Fuel Pressure Regulator The throttle body (9E926) for this vehicle is a
sludge-resistant design and should not be cleaned.
(Continued)
ALL RIGHTS RESERVED
CLEANING AND INSPECTION (Continued) SPECIAL SERVICE TOOLS/EQUIPMENT
Fuel Injector SPECIAL SERVICE TOOLS REQUIRED
Testing Tool Number /

Description IIIu8tration
Test fuel injectors (9F593) using Rotunda Fuel Injector
Tester/Cleaner 113-00001 or equivalent. Follow tool T80l -9974-B
manufacturer's operating instructions. Multiport Fuel Injection (MFI)
Fuel Pressure Gauge (EFI/ CFI
Fuel Pressure Gauge)
ADJUSTMENTS
T80L-1174-B
Idle Speed
T81 P-19623-G2
Refer to Powertrain Control/Emissions Diagnosis Spring lock Coupling
4
Manual (080-1) for Idle Speed Diagnosis Procedure. Disconnect Tool (1 /2 Inch)
SPECIFICATIONS
TI1P·11123-G2
TORQUE SPECIFICATIONS T81 P-19623-G 1

Description N·in Lb-Ft Lb-In Spring lock Coupling
Disconnect Tool (3/ 8 Inch)
EGRTube 34-47 25-35
EGR Valve to Upper Intake 8-11 - 70-97
Manifold
Air Supply Tube Clamps 1.3-2.25 - 12-20 TI1p·11123-G1
Upper Intake Manifold to 16-24 12-18 -

lower Intake Manifold Bolts ROTUNDA EQUIPMENT
Throttle Body to Upper Intake 8-11 - 71-97 Model De8crlptlon
Manifold
113-00001 Fuel Injector Tester / Cleaner
Idle Air Control Valve to lower 8-11 - 71-97
Intake Manifold
Throttle Position Sensor to 2.0-3.0 - 18-27
Throttle Body
Fuel Pressure Regulator to 3-5> - 27-42
Fuel Injection Supply Manifold 8-12 - 71-106
Retaining Bolts
Coil Bracket to Platform 6-10 - 53-89
Throttle Cable Bracket to 11-13 8-10 -
Manifold


ALL RIGHTS RESERVED
03-040-1 Fuel Charging and Controls, 5.8L Lightning Engine 03-040-1
SECTION 03·040 Fuel Charging and Controls, 5.8L

Lightning Engine
VEHICLE APPLICATION .........................................•.03-040.1 REMOVAL ANO INSTALLATION
OESCRIPTION ANO OPERATION Fuel Charging System 03-040.7
A/C Compressor Clutch Control Relay 03-040-6 Fuel Charging Wiring .......................................•.03-040-12
Air Induction System ............................•.....•........03-040-2 Fuel Injection Supply Manifold 03-040-11
Fuel Charging Wiring ................•..........................03-040-5 Fuel Injector ..............•.......................................03-040-10
Fuel Injection Supply Manifold 03-040-4 Fuel Pressure Regulator 03-040-12
Fuel Injection Timing 03-040-2 Fuel Pressure Relief Valve 03-040-11
Fuel Injectors ............................•.........................03-040-4 Fuel Pump Relay O3-040-12
Fuel Pressure Regulator ..............................•.....•.03-040-5 Spring Lock Coupling 03-040-8
Fuel Pressure Relief Valve ..........•.....•..................03-040-5 Throttle Body ....................................................•.03-040-9
Fuel Pump Relay .................................•••....•.........03-040-6 CLEANING ANO INSPECTION
Fuel System .......................••...............................03-040-1 Cleaning 03-040-13
Inertia Fuel Shutoff (lFS) Switch............•..............03-o40-6 Fuel Injector 03-040-12
Intake Manifold 03-040-3 Idle Air Control Valve .•.......................................03-040-13
Multiport Fuel Injection (MFI) 03-040-2 Throttle Body 03-040-12
Throttle Body ..............................................•.......03-040-3 AOJUSTMENTS
OIAGNOSIS ANO TESTING Idle Speed .....•...................................................03-040-13
Fuel Charging and Controls 0~~40-7 SPECiFiCATIONS................................•.................03-040-14
Tips to Avoid Lean Air-Fuel Conditions ...............•.03-o40-7 SPECIAL SERVICE TOOLS/EQUIPMENT 03-040-14
VEHICLE APPLICATION
Lightning Truck
Fuel System The fuel delivery subsystem consists of a

high-pressure in-tank mounted fuel pump and a fuel
WARNING: DO NOT SMOKE, CARRY LIGHTED
filter f reservoir delivering fuel from the fuel tank
SUBSTANCES OR OPEN FLAME OF ANY TYPE
through a 20 micron fuel filter to a fuel charging
WHEN WORKING ON OR NEAR ANY
manifold assembly.
FUEL-RELATED COMPONENT. HIGHLY
FLAMMABLE MIXTURES ARE ALWAYS PRESENT The fuel injection supply manifold (9F792)
AND MAY BE IGNITED, RESULTING IN POSSIBLE incorporates electrically actuated fuel injectors
PERSONAL INJURY. (9F593) mounted directly above each of the engine's
intake ports. The fuel injectors, when energized, spray
A powertrain control module (PCM)( 12A650) accepts
a metered quantity of fuel into the intake air stream.
input from various engine sensors to compute the
required fuel flow rate necessary to maintain a A constant fuel pressure drop is maintained across the
prescribed air ffuel ratio throughout the entire engine fuel injectors by a fuel pressure regulator (9C968).
operational range. The powertrain control module then The fuel pressure regulator is connected in series with
outputs a command to the fuel injectors to meter the the fuel injectors and is positioned downstream from
appropriate quantity of fuel. them. Excess fuel supplied by the pump, but not
required by the engine, passes through the fuel
pressure regulator and returns to the fuel tank through
compensates for the age of the vehicle and its
a fuel return line.
compensate for changes in altitude (Le., from sea level
to mountains).

ALL RIGHTS RESERVED
Fuel Injection Timing Air Induction System

All eight fuel injectors (9F593) are energized The air induction system supplies filtered air to the
simultaneously, once every crankshaft revolution. The engine to mix with the fuel for combustion purposes.
period of time that the fuel injectors are energized (fuel The air induction system consists of an engine air
injector "on time" or pulse width) is controlled by the cleaner intake tube and duct (9A673), air cleaner
powertrain control module (PCM)( 12A650). The assembly with filter, air cleaner outlet tube, mass
powertrain control module receives input from various airflow sensor, throttle body inlet tube, throttle body
engine sensors and uses this information to compute (9E926) and intake plenum.
the required fuel flow rate necessary to compute the
prescribed air /fuel ratio for the given engine
operation. The powertrain control module determines
the needed injector pulse width and outputs a
command to the fuel injector to meter the exact
quantity of fuel.
EGR
VALVE
FUEL INJECTOR
9E527
Part
"""
FRONT OF ENGINE 2
3
90476
9E464
Gasket, EGR-to-EGR Spacer
Plate
Gasket, EGR Spacer
Plate-to-Upper Intake
5 9H474 EGR Spacer Plate
6 9E933 Gasket, Throttle
Body-to-EGR Spacer Plate
8 45357 Nut, 5/16-18 (4 Req'd)
Throttle Body-to-EGR
Spacer
~ 10 9S557 Throttle Position Sensor
LOWER INTAKE
MANIFOLD
Cover
9424 A - Tighten to 17-24 N·m
A17861-B
(13-18 Lb-Ft)
Multiport Fuel Injection (MFI)

The multiport fuel injection system (MFI) is classified
injection system. Fuel injectors pulse in accordance
with engine demand.

ALL RIGHTS RESERVED
Throttle Body
..
The throttle body (9E926) controls airflow to the
engine through a butterfly-type valve. The throttle
body is a single-piece die casting made of aluminum. It
has a single bore with an air bypass channel around
the throttle plate. This bypass channel controls both
cold and warm engine idle airflow as regulated by an FRONT OF
air bypass valve assembly mounted directly to the ENGINE
throttle body. The air bypass valve assembly is an
electro-mechanical device, controlled by the
powertrain control module (PCM)( 12A650), that
meters the amount of air bypassed around the throttle
plates in order to control engine idle speed. Engine
coolant is diverted through the EGR spacer to improve
cold weather operation.
Other features of the air throttle body include:
1. A preset stop to locate the WOT position.
(TP sensor)(98989).
3. Sludge resistant coating applied to the
downstream side of the throttle plate and bore
area to reduce plate-to-bore leakage. The
coating should not be removed or cleaned.
4. The plate position at idle is set by the throttle
return control (TRC) screw contacting the throttle
lower arm. DO NOT adjust or tamper with this
screw unless instructed to do so by the
Powertrain Control/Emissions Diagnosis
1
Manual.
Intake Manifold
The intake manifold (9424) is a two-piece (upper and
lower) assembly. The lower intake manifold is cast
aluminum. The upper intake manifold is of a welded
tubular design. Runner lengths are tuned to optimize
engine torque and power output. The intake manifold
provides mounting flanges for the throttle body
(9E926), fuel injection supply manifold (9F792) and
accelerator control bracketry and the EGR external
pressure valve (9F483). Vacuum taps are provided to
support various engine accessories. Pockets for the
fuel injectors (9F593) are machined to prevent both air
and fuel leakage. The pockets in which the fuel
injectors are mounted are placed to direct the injector
fuel spray immediately in front of each engine intake
valve (6507).
1 May be purchased as a separate item.


ALL RIGHTS RESERVED
Fuel Injectors
Part
The eight fuel injectors (9F593) are
electro-mechanical devices which both meter and
atomize fuel delivered to the engine. The MFI fuel 3 - Coil (Part of 9F593)
injectors are mounted in the lower intake manifold 4 - Armature (Part of 9F593)
(9424) and are positioned so that their tips direct fuel 5 - Washer (Part of 9F593)
just ahead of the engine intake valves (6507). The fuel 6 - Lower Intake Manifold
injector consists of a solenoid and valve assembly. An O-Ring (Part of 9F593)
electrical control signal from the powertrain control 7 - End Cap (Part of 9F593)
module (PCM)( 12A650) activates the injector 8 - Stainless Steel Valve Body
solenoid, causing the needle to move inward off the (Part of 9F593)
seat, allowing fuel to flow. Since the injector flow 9 - Stainless Steel Needle
orifice is fixed and the fuel pressure drop across the (Pintle) (Part of 9F593)
fuel injectors tip is constant, fuel flow to the engine is 10 - Electrical Connector
regulated by how long the solenoid is energized. (Part of 9F593)
Atomization is obtained by a director metering plate at
the point where the fuel separates. The 5.8L Lightning Engine is equipped with Deposit
Resistant Injectors (DRI). This fuel injector is designed
to eliminate the lean fuel delivery concerns which
occur with conventional multiport fuel injectors when
low-grade, non-detergent fuels are used.

high pressure fuel from the vehicle fuel supply line to
the eight fuel injectors (9F593). The assembly
consists of two banks of tubular fuel injection supply
manifolds connected by two permanent crossover
flange to the fuel pressure regulator (9C968) and
mounting attachments which locate the fuel injection
supply manifold and provide fuel injector retention. The
fuel inlet and outlet connections have push-connect
fittings. The unit is serviced as an assembly only.
FUEL
PRESSURE . . FRONT OF ENGINE
REGULATOR
9C968 FUEL INJECTION
SUPPLY MANIFOLD
9F792
A19017-B
Part A17~
1 - Supply Manifold O-Ring
(Part of 9F593)
2 - Integral Filter
(Part of 9F593)
(Continued)

ALL RIGHTS RESERVED
03-04D-5 Fuel Charging and Controls, 5.8l lightning Engine 03-04D-5

Part
The fuel pressure regulator (9C968) is attached to the
fuel injection supply manifold (9F792) downstream of
the fuel injectors (9F593). It regulates the fuel 4 - Upper Housing
pressure supplied to the fuel injectors. The fuel (Part of 9C96a)
pressure regulator is a diaphragm-operated relief 5 - Diaphragm (Part of 9C96a)
valve in which one side of the diaphragm senses fuel 6 - Lower Housing
pressure and the other side is subjected to intake (Part of 9C96a)
manifold vacuum. The nominal fuel pressure is 7 - Fuel Outlet Tube (Return)
established by a spring preload applied to the (Part of 9C96a)
diaphragm. Balancing one side of the diaphragm with a - Fuel Inlet Tube (Supply)
manifold pressure maintains a constant fuel pressure (Part of 9C96a)
drop across the fuel injectors. Fuel in excess of that 9 - O-Ring Grooves
used by the engine is bypassed through the fuel (Part of 9C96a)
pressure regulator and returns to the fuel tank. 10 - Mounting Plate
(Part of 9C96a)
(Part of 9C96a)
12 - Spring Seat (Part of 9C96a)
13 - Valve Assembly
(Part of 9C96a)
, Fuel Pressure Relief Valve

The fuel pressure relief valve (9H321) is used to
relieve fuel pressure from the fuel system. The fuel
pressure relief valve is located on the fuel injection
supply manifold (9F792). For fuel system pressure
relief procedures refer to Section 10-01A or 10-01B.

V7787-C electronic engine controls such as throttle position
(lAC valve)(9F715). The fuel charging wiring receives
Part signals from the powertrain control module
Item Number Description (PCM)( 12A650) and transfers the signals to the fuel
injectors. The signals from the powertrain control
module determine the fuel injectors sequence and
Tube (Part of 9C96a)
duration each fuel injector will stay open to allow fuel
2 - Ball Seat (Part of 9C96a)
into the combustion chambers.
3 - Spring (Part of 9C96a)
(Continued)

ALL RIGHTS RESERVED

Part
The inertia fuel shutoff switch (IFS switch)(934 1) is Number Description
Item
used in conjunction with an electric fuel pump. The
purpose of the inertia fuel shutoff switch is to shut off 3 - Target Plate (Part of 9341)
the fuel pump in the event of a collision. It consists of a 4 - Ball (Part of 9341)
steel ball held in place by a magnet. When a sharp 5 - Magnet (Part of 9341)
impact occurs, the ball breaks loose from the magnet, 6 - Reset Button Position for
rolls up a ramp and strikes a target plate which opens Open Switch (Part of 9341)
the electrical contacts of the inertia fuel shutoff switch 7 - Closed Switch (Part of 9341)
before restarting the vehicle.
Fuel Pump Relay
when the powertrain control module (PCM)( 12A650)
grounds the relay during START and engine RUNNING
conditions.
AIC Compressor Clutch Control Relay

The A / C cutoff relay is used to improve idle
smoothness after engine start-up and to improve
acceleration performance. The A / C is cut off for
approximately 5 seconds under the following
CUTAWAY.~E~ conditions: just after the engine is started, and when
the throttle position sensor (TP sensor)(9B989)
indicates a wide-open throttle condition .
......----17
EXTERNAL VIEW A23669-A
Part
1 - Electrical Contacts
(Part of 9341)
2 - Switch Terminals
(Part of 9341)
(Continued)

ALL RIGHTS RESERVED
Fuel Charging and Controls Pre-Service Procedures

Refer to the Powertrain Control/Emissions Diagnosis The fuel charging assembly consists of the throttle
2
Manual (OBD-I). body (9E926), and the upper and lower intake
manifolds (9424). Prior to service or removal of the
fuel charging assembly, the following steps must be
taken:
Tips to Avoid Lean Air-Fuel Conditions 1. Disconnect battery ground cable battery lead and
Rough idle, hesitation, poor throttle response, secure it out of the way. Remove the fuel supply
induction backfire and stalls during cold manifold shield (9J314).
start / warm-up may be caused by the poor volatility of 2. Remove engine air cleaner intake tube and duct
some high octane premium grade unleaded fuels (91 (9A673) from air cleaner to throttle body.
octane or higher (R+M) / 2). When compared to 3. Remove fuel tank filler cap (9030) to relieve tank
regular grade unleaded fuel (87 octane (R+M) /2), pressure.
high octane premium grade unleaded fuel may cause
long crank time. 4. Release pressure from fuel system at fuel
pressure relief valve (9H321) (Schrader) on fuel
Use a regular grade unleaded fuel except where a injection supply manifold (9F792). Use Multiport
premium unleaded fuel is recommended in the owner Fuel Injection Fuel Pressure Gauge (EFI / CFI Fuel
guide. If lean air-fuel type symptoms are experienced, Pressure Gauge) T80L-9974-B. To gain access
determine the grade and brand of fuel used and offer to fuel pressure relief valve, valve cap must first
the following service tips. be removed.
• Advise those using a higher o-ctane grade fuel to Post-Service Procedures
switch to a regular grade unleaded fuel. For those
using a regular grade fuel, advise them to try After the service is complete and the fuel charging
another brand. assembly is installed onto engine, the following steps
must be taken:
• Do not advise using a higher octane unleaded fuel
than is recommended for that specific engine. The 1. Install engine air cleaner intake tube and duct to
5.8L Lightning engine is designed to perform best throttle body.
using a high quality regular grade unleaded fuel. 2. Install the fuel tank filler cap.
• Only advise using a higher octane unleaded fuel to 3. Connect battery ground cable.
avoid potentially damaging spark knock or ping, but
4. NOTE: Check all connections at fuel rails,
do so only after mechanical repairs are ineffective.
push-connect fittings, fuel injectors, etc.
• All unleaded gasolines used should contain CAUTION: The fuel system is normally
detergent additives that are advertised as having
"keep clean" or "clean up" performance for both
intake valves (6507) and fuel injectors. Turn ignition switch (11572) on and off several
times without starting engine to pressurize the
The 5.8L Lightning engine is designed to run on regular
fuel system. Check for fuel leaks at fuel pressure
unleaded fuel under normal driving operations. When
regulator (9C968), fuel injectors and fuel connect
towing a trailer or carrying a load, the engine will run
fittings.
most effectively on premium fuel (91 octane or higher
is recommended). Using a fuel with a lower octane 5. Start engine and warm to operating temperature.
rating can cause persistent and heavy knocking, Check for coolant leak if coolant was removed.
which can damage the engine. Refer to Symptom Chart and Pinpoint Test A in
Section 03-03.
Manual 2 for further diagnosis and testing procedures. 6. Perform EEC self test to check system's function.
2

Multiport Fuel Injection Fuel Pressure T80l-9974-B
Gauge (EFI / CFI Fuel Pressure Gauge)


ALL RIGHTS RESERVED
03-04D-8 Fuel Charging and Controls, 5.8L Lightning Engine 03-04D-8

SPECIAL SERVICE TOOL(S} REQUIRED

together by a garter spring inside a circular cage.
When the coupling is connected together, the flared
end of the female fitting slips behind the garter spring
inside the cage of the male fitting. The garter spring
and cage then prevent the flared end of the female
fitting from pulling out of the cage. As a redundant
locking feature, a horseshoe shaped retaining clip is
incorporated to improve the retaining reliability of the ®
spring lock coupling.
MALE CUPITETHER ASSY

FITTING
SPRING-LOCK
COUPLING V7329-A
Removal
1. Release fuel system pressure. Refer to Section
10-0 1A for fuel system pressure relief
procedures. A fuel pressure relief valve (9H321) @
on the fuel injection supply manifold (9F792) is V4803·D
provided for this procedure.
Installation
2. Remove retaining clip from spring lock coupling
by hand only. Do not use any sharp tool or WARNING: USE ONLY THE SPECIFIED O-RINGS
screwdriver as it may damage the spring lock AS THEY ARE MADE OF A SPECIAL MATERIAL.
coupling. THE USE OF ANY O-RING OTHER THAN THE
SPECIFIED O-RING MAY ALLOW THE
3. Twist fitting to free it from any adhesion at the
CONNECTION TO LEAK INTERMITTENTLY
O-ring seals.
DURING VEHICLE OPERATION.
4. Using Spring Lock Coupling Disconnect Tool
1. Make sure the garter spring is in cage of male
T81 P-19623-G 1 (3/8 Inch) or T81 P-19623-G2
fitting. If garter spring is missing, install a new
(1 /2 Inch), disconnect fuel hoses at the fuel rail
spring by pushing it into cage opening. If garter
spring is damaged, remove it from cage with a
a. Fit tool to coupling so tool can enter cage to small wire hook (do not use a screwdriver) and
release garter spring. install a new spring.
b. Push the tool into the cage opening to release 2. Clean all dirt or foreign material from both pieces
female fitting from garter spring. of coupling.
c. Pull the coupling male and female fittings 3. Replace missing or damaged O-rings. Use only
apart. O-rings listed in Spring Lock Coupling illustration.
d. Remove the tool from the disconnected 4. Lubricate male fitting and O-rings and inside of
coupling. female fitting with clean engine oil
XO-10W30-QSP or equivalent meeting Ford
specification ESE-M2C 153-E.
fitting.
6. Ensure coupling engagement by pulling on fitting
and visually checking to make sure garter spring
is over flared end of female fitting.

ALL RIGHTS RESERVED
7. NOTE: All vehicles require the large black clip to 5. Connect throttle cable bracket.
be installed on the supply side fuel line and the 6. Connect cooling hoses to EGR spacer and secure
small gray clip to be installed on the return side with clamps.
fuel line.
7. Position AIRB I AIRD bracket to EGR spacer and
Position retaining clip over metal portion of spring install attaching nuts.
spring lock coupling. Make sure horseshoe 8. Connect electrical connectors at throttle position
portion of clip is over the coupling. Do not install sensor and idle air control valve.
retaining clip over rubber fuel line. 9. Connect PCV fresh air hose to throttle body and
to oil fill tube.
10. Check and fill cooling system as required.
Throttle Body 11. Install fuel supply manifold shield and engine air
cleaner intake tube and duct.
Removal
1. Open hood, disconnect battery negative cable and reconnected, some abnormal drive
and remove fuel supply manifold shield (9J314). symptoms may occur while the powertrain
2. Remove engine air cleaner intake tube and duct control module (PCM)( 12A650) relearns its
(9A673). adaptive strategy. The vehicle ma~ need to be
3. Remove PCV fresh air hose from throttle body
(9E926) and oil fill tube. Connect battery negative cable. Start engine and
check for proper operation.
4. Disconnect electrical connectors from throttle
position sensor (TP sensor)(9B989) and idle air
control valve (lAC valve)(9F715).
5. Loosen radiator cap to relieve cooling system
pressure (allow engine to cool first). Remove and
plug cooling hoses from EGR spacer.
6. Remove AIRBI AIRD bracket attaching nuts,
remove bracket from EGR spacer and place out
of way.
7. NOTE: Some coolant will be lost from EGR
spacer when throttle body is removed.
Remove throttle body attaching nuts and throttle
cable bracket.
8. Separate throttle body from EGR spacer.
cable from ball stud, use a screwdriver or
similar tool close to the stud and pry slowly.
Pulling by hand may damage cable.
Disconnect throttle cable at throttle ball stud,
then remove throttle body from vehicle.
10. Remove EGR spacer from upper intake manifold
(9424).
Installation Part
damage gasket surfaces, or allow material to fall 1 9F483 EGR External Pressure Valve
into upper intake manifold. 2 90476 Gasket, EGR-to-EGR Spacer
Plate
Clean and inspect all gasket surfaces.
3 9E464 Gasket, EGR Spacer
2. NOTE: The EGR spacer-to-intake manifold Plate-to-Upper Intake
gasket and the throttle body-to-EGR spacer 4 9424 Intake Manifold
gasket are very similar to each other but are NOT 5 9H474 EGR Spacer Plate
to be interchanged. 6 9E933 Gasket, Throttle
Position new EGR spacer gasket onto studs and Body-to-EGR Spacer Plate
install EGR spacer. 7 9F715 Idle Air Control Valve
3. Connect throttle cable to throttle body. 8 45357 Nut, 5/16-18 (4 Req'd)
Throttle Body-to-EGR
4. Position new throttle body gasket onto studs and Spacer
install throttle body. Install mounting nuts and (Continued)
tighten to 17-24 N·m (13-18 Ib-ft).

ALL RIGHTS RESERVED
Part
10 9S557 Throttle Position Sensor
Cover
(13-18 Lb-Ft)
O-RING
'SEALS
Fuel Injector
Removal
1. Perform all pre-service procedures as described
in this section.
2. Remove upper intake manifold (9424) and fuel V5040-B
injection supply manifold (9F792) as described in
this section. Installation
3. Carefully disconnect electrical connectors from 1. CAUTION: Never use silicone grease. It will
injectors. clog the fuel InJectors.
4. Grasping injector body, pull up while gently Lubricate new O-rings with 10W-30 oil or
rocking fuel injector (9F593) from side to side. equivalent meeting Ford specification
ESE-M2C 153-E and install two on each injector.
INJECTOR 2. Install fuel injectors using light, twisting, pushing
POCKETS motion.
(8)
3. Connect electrical connectors to fuel injectors.
in this section.
5. Install upper intake manifQld as described in this
section.
in this section.
5. CAUTION: 00 not attempt to clean the

Injector metering orifice with tools or
brushes. Injectors are deposit resistant and
require no cleaning.
Inspect fuel injector O-rings (two per injector) for
A19018-A

ALL RIGHTS RESERVED

Multiport Fuel Injection Fuel Pressure T80L-9974-B
Gauge (EFI / CFI Fuel Pressure Gauge)
1. NOTE: Fuel pressure relief valve cap (9H323) on fA\

fuel pressure relief valve (9H321) must be \!y
removed. -------------------
If fuel injection supply manifold (9F792) is
mounted to engine, remove fuel tank filler cap
(9030), then release pressure from system at fuel
pressure relief valve on fuel injection supply
manifold, using Multiport Fuel Injection Fuel @
Pressure Gauge (EFI/CFI Fuel Pressure Gauge) ~~~~~~~~~~~~~~~~~~
T80l-9974-8.
2. Using an open-end wrench or suitable deep-well
socket, remove fuel pressure relief valve.
Installation
1. Install fuel pressure relief valve and fuel pressure ©
reliefva~ecap.~ghtenfuelpressurereli~va~e ~~ ~_ _- - - -
to 7. 75 N·m (69 Ib-in) and the fuel pressure relief
valve cap to 0.6 N·m (5.3Ib-in).

Description Tool Number @ V4803-D
4. Remove four (two per group) fuel supply manifold
retaining bolts.
Removal 5. Carefully disengage intake manifold from fuel
1. Perform all pre-service procedures as described injectors (9F593) and remove intake manifold.
in this section. Installation
2. Remove upper intake manifold (9424). Refer to 1. Make sure injector end caps are clean and free of
Section 03-01 B. contamination.
3. Using Spring lock Coupling Disconnect Tool 2. Place the fuel injection supply manifold (9F792)
T81 P-19623-G 1 (3 I 8 Inch) or T81 P-19623-G2 over each of the fuel injectors, making sure the
(1 12 Inch), disconnect fuel hoses at the fuel rail fuel injector-s are fully seated in both the supply
supply tube and fuel rail return tube. manifold and lower intake manifold.
a. Fit tool to coupling so tool can enter cage to 3. Install four retaining bolts and tighten to 8-17 N·m
release garter ,pring. (70-150 Ib-in).
b. Push the tool into the cage opening to release 4. Connect fuel supply and return lines to fuel
female fitting from garter spring. injection supply manifold as follows:
c. Pull the coupling male and female fittings a. Check for missing or damaged garter spring.
apart. Remove damaged spring with small hooked
d. Remove the tool from the disconnected tool and install new spring.
coupling. b. Clean fittings with solvent. Check for missing
or damaged O-rings. Replace missing
a-rings. If either a-ring is damaged, replace
both. O-rings.
.c. Assemble fitting by pushing with a slight
twisting motion.
ALL RIGHTS RESERVED
03-04D-12 Fuel Charging and Controls, 5.8L Lightning Engine 03-04D-12
d. To make sure of coupling engagement, pull on 2. CAUTION: Never use silicone grease to
fitting and visually check to be sure garter lubricate O-ring.
spring is over flared end of female fitting. Lubricate fuel pressure regulator O-ring with
10W-30 oil or equivalent meeting Ford
REPLACEMENT GARTER SPRINGS specification ESE-M2C153-E.
GARTER 3/8 INCH - E1ZZ-19E576-A*
SPRING 1/2 INCH - E1ZZ-19E576-B*
3. Install O-ring and new gasket on fuel pressure
5/8 INCH - E35Y-19E576-A* regulator.
3/4 INCH - E69Z-19E576-A
4. Position fuel pressure regulator and install Allen
screws. lighten screws to 3-4 N·m (27-35 Ib-in).
in this section.
*ALSO AVAILABLE IN 6. Perform all post-service procedures as described
E35Y-19D690-A KIT WITH O-RINGS
in this section.
7. Start engine and check for proper operation.
O-RINGS

GARTER described in this section.
SPRING
2. Disconnect fuel charging wiring (9D930) from fuel
injectors (9F593) and electronic engine controls.
3. Remove fuel charging wiring ground strap
V5908-C
control sensor wiring (12A581).
5. Install fuel supply and return line retaining clips. 5. To install, reverse Removal procedure. Verify all
connections. .
section.
in this section. Fuel Pump Relay
8. Start engine and check for proper operation. Removal and Installation
2. Locate relay (14N089), located in the engine
Fuel Pressure Regulator compartment power distributor center, and
remove relay.
Removal
1. Perform all pre-service procedures as described
in this section.
2. Remove fuel injection supply manifold (9F792) as CLEANING AND INSPECTION
3. Remove two Allen screws and remove fuel Throttle Body
pressure regulator (9C968) from regulator
housing. NOTE: The throttle body (9E926) for this vehicle is a
sludge resistant design and should not be cleaned.
4. Remove both O-rings and return seal. Discard
return seal and inspect both O-rings for signs of
deterioration. .
Installation Fuel InJector
1. NOTE: If scraping is necessary, be careful not to Testing
damage mating surfaces.
Test fuel injectors (9F593) using Rotunda Fuel Injector
Clean and inspect fuel pressure regulator and Tester / Cleaner 113-00001 or equivalent. Follow tool
regulator housing mating surfaces. manufacturer's operating instructions.

ALL RIGHTS RESERVED
Idle Air Control Valve 15. Reattach the control signal lead to the idle air
CAUTION: This cleaning procedure may be used control valve.
with sludge tolerant bodies which are identified 16. Check the engine for normal operation.
with a yellow/black "attention" label. No attempt
should be made to clean the throttle body
(9E926) bore/plate area by directly spraying or
scrubbing. Cleaning
1. Plug the actuator into the connector in Rotunda NOTE: To be used only when tools for the preferred
Air Bypass Valve Actuator 113-00009 or method are not available.
equivalent.
Remove the idle air control valve (lAC valve)(9F715)
2. Remove the engine air cleaner intake tube and from the throttle body (9E926). Remove the electrical
duct (9A673) to the throttle body inlet. solenoid assembly from the mechanical portion of the
3. Disconnect the idle air control valve signal lead. idle air control valve by removing the two screws, then
sliding the mechanical portion away from the solenoid.
4. Attach the actuator harness plug to the idle air
control valve (lAC valve)(9F715). CAUTION: 00 not exceed three minutes soak
time, and do not use choke cleaner as an internal
5. Start the actuator and then start the engine.
O-ring may begin to deteriorate.
CAUTION: Avoid direct spraying on throttle
Soak the mechanical portion in Carburetor Tune-Up
plate/bore area.
Cleaner D9AZ-19579-BA or equivalent meeting Ford
6. Spray Carburetor Tune-Up Cleaner specification ESR-M 14P9-A for two to three minutes
D9AZ-19579-AA or equivalent for about five maximum.
seconds into the idle air control valve inlet
With the mechanical portion completely submerged,
passage while the actuator is operating.
shake in all directions: up, down, right and left. Then
7. Stop the engine and actuator. Let everything push in on the rod that mates with the solenoid
soak for 15 minutes. assembly, and again shake in all directions with the
8. Start the actuator and then start the engine. unit submerged and the rod held in as far as possible.
9. Spray the Carburetor Tune-up Cleaner into the Remove the unit from the cleaning fluid and dry out
idle air control valve passage leading to the inlet thoroughly with compressed air.
of the valve for up to one minute.
10. Stop the actuator and stop the engine.
ADJUSTMENTS
11. Reinstall the air duct.
12. Start and run the engine for about one minute to Idle Speed
dry out the solvent residue.
13. Operate the actuator to make sure the solvent is Manual (OBO-I)3 for idle speed adjustment
purged from the idle air control valve. procedures.
14. Disconnect the actuator from the idle air control
valve.

ALL RIGHTS RESERVED
SPECIFICATIONS

Description N·m Lb-Ft Model Description
Nut and Washer Assembly, EGR 17-24 12-18 113-00001 Fuel Injector Tester / Cleaner
Retaining, Both Air Bypass Valve Actuator
113-00009
Stud, Throttle Body and EGR 17-24 12-18
Spacer Plate Mounting,
5 I 16-18-18 x 4. 12
Nut, Throttle Body-to-EGR Spacer 17-24 12-18
Plate Retaining (4 Required)
Bolts, Upper Intake Manifold 17-24 12-18
Retaining
Bolts and Studs, Lower Intake 31-33 23-25
Manifold Retaining
Screws, TP Sensor Retaining 2 18
(Lb-In)
Screws, Idle Air Control Valve 8-11 71-97
Retaining (Lb-In)
Screws, AIRBI AIRD Solenoid 16-24 12-18
Bracket Retaining
Bolts, Fuel Injection Supply 8-17 70-150
Manifold (Lb-In)
Screws, Fuel Pressure Regulator 3-4 27-35
(Lb-In)
Fuel Pressure Relief Valve 7.75 69
(Lb-In)
Fuel Pressure Relief Valve Cap 0.6 5.3
(Lb-In)

Tool Number/
TSOL-9974-B
Pressure Gauge (EFI I CFI Fuel
Pressure Gauge)
TIOL·1I74-8
T81 P-19623-G2
Disconnect Tool (1/2Inch)
TI1 P-11123-G2
T81 P-19623-G 1
Disconnect Tool (3 I 8 Inch)
TI1P·1t123-G1

ALL RIGHTS RESERVED
03-04E-1 Fuel Charging and Controls, 7.3L Diesel 03-04E-1
SECTION 03·04E Fuel Charging and Controls, 7.3L

Diesel
VEHICLE APPLICATION 03-04E-1 DESCRIPTION AND OPERATION .•...•..•••••••...•...•...•..•03-o4E-1
VEHICLE APPLICATION


ALL RIGHTS RESERVED
03-04F-1 Turbocharger, 7.3L DI Turbo Diesel Engine 03-04F-1
SECTION 03·04F Turbocharger, 7.3L DI Turbo Diesel

Engine
VEHICLE APPLICATION ......•...•............................•...03-04F-1 DESCRIPTION AND OPERATION 03-04F-1
VEHICLE APPLICATION

ALL RIGHTS RESERVED
03-05-1 Drive Belts, Accessory 03-05-1
SECTION. 03~Q~_Dl1ve Belts,-Accessory

VEHICLE APPLICATION ..••••••.••.•.•••.....••.••••.••...•••.••••••03-05-1 REMOVAL AND INSTALLATION (Cont'd.)
DESCRIPTION AND OPERATION Fan and Clutch, 7.3L Dlesel •••••••••.••••••••••••••••••••••••03·0S·11
Drive Belts, Accessory ••.•••••••••.••••.•..••••.•.•••.•.••..•••••03-05-1 ADJUSTMENTS
DIAGNOSIS Drive Belt Tension Adjustment, Automatically
Component Tests •.•.••••...••••••••.•••••....••••.••••••••.•••.•••03-05-5 Tensioned Belts .••••••.•••••••••••••••••••••••••••••••••••••••03-05·14
Inspection and Verification •..•••••••••••••...••...••••••••.••.03-05-3 Drive Belt Tension AdJustinent, Manually
Symptom Chart••••••••••••......••.••.••••••••.•.•.•••••••..••••.•••03-05-4 Tensioned Belts, 7.5L Gasoline Engine •••••••••••••03-05·13
REMOVAL AND INSTALLATION Power Steering Pulley Alignment •••••••••••••••••••••••••03-05·14
Belt Tensloner Pulley Replacement ••.•••••••..••••.•••••03-05-10 SPECIFICATIONS ••••••••••••••••••.••.•••••••••••••..••.•••••••..•••03-05·15
Drive Belt Replacement ••.••••••.••••.•...••••...••••..•••••••••03·05·8 SPECIAL SERVICE TOOLS/EQUIPMENT ••••••••••••••••••03-05-15
Fan and Clutch, 4.9L MFI ••••••.••.•••.•••••••.••••••...•••.•••03·0S·10
Fan and Clutch, 5.0L, S.8L and 7.SL
Engines •••••••••.•.•••••••••••....•.••..••••....•.••••••••...•.••.•03·05-11
VEHICLE APPLICATION
F-Series, Bronco
Drive Belts, Accessory The drive belts (except for 7.5L generator belt) are
tensioned by an automatic belt tensioner which
Ford vehicles are equipped with poly-V drive belts
maintains proper belt tension at all times. The 7.5L
(8620). To ensure maximum belt life, replacement
generator belt is not automatically tensioned and
drive belts should be of the same type and
requires periodic tensioning.
specification as originally installed.
Loose drive belts will result in slippage which may
cause a noise complaint or improper accessory
operation (generator (GEN)(10300) will not charge,
etc.). Overly tight drive belts will place severe loads on
accessory bearings and result in premature drive belt
or accessory failure. Refer to the illustrations in this
section for the belt routing of each particular engine
(6007).
Q4052·A
ALL RIGHTS RESERVED
03·05·2 Drive Belts, Accessory 03·05·2
Accessory Drive Belt, 4.9L MFI Engine
FRONT OF ENGINE
~
DRIVE BELT
8620
TENS
INSTALLATION wrntOUT AlC INSTALLAnON WITH AlC
Q2475-G
Accessory Drive Belt, 5.0L and 5.8L MFI Engines

Part
7 9B447 Secondary Air Injection
Pump Pulley
Accessory Drive Belt, 7.3L Diesel Engine
02601-F
Part
1 10300 Generator
Q4235-A
3 2E884 AIC Clutch Pulley, with AIC
8678 Belt Idler Pulley, Without Part
AIC
4 3A733 Power Steering Pump Pulley
5 8509 Water Pump Pulley 1 10300 Generator
6 6312 Crankshaft Pulley 2 8678 Belt Idler Pulley
ALL RIGHTS RESERVED
Part ACCEPTABLE
3 2E884 A / C Clutch Pulley
4 2A451 Vacuum Pump
CRACKS PERPENDICULAR
TO RIBS
6 6312 Crankshaft Pulley NOT
7 8509 Water Pump Pulley ACCEPTABLE
Accessory Drive Belt, 7.5L MFI Engine
CHUNKS OF RIBS MISSING 04077-8
Drive Belt Noise/Flutter

Drive belt chirp is a regularly occurring "chirping"
noise that occurs due to pulley misalignment or
excessive pulley runout. It can be a result of a
damaged pulley or an improperly replaced pulley that
was not properly aligned.
To correct, determine the area where the noise comes
from. Then check each of the pulleys in that area with
a straightedge to the crankshaft pulley (6312) and
look for the accessory pulleys to be out of position in
the fore / aft direction or at an angle to the
straightedge.
Belt squeal is an intermittent noise that occurs when
7.ILENGINE the drive belt slips on a pulley during certain conditions
such as: engine start-up, rapid engine acceleration, or
A I C clutch engagement.
Ale OR IDLER
Ale Drive belt squeal can occur under the following
conditions:
TEN. ALT.
1. If the A I C discharge pressure goes above 2895
W/P kPa (420 psi). This can occur if:
a. The A/C system is overcharged.
PIS
b. The A/C condenser core airflow is blocked.
CIS c. The fan blade (8600) is not engaging fully at
idle.
i BELT'1
2. If A/C OFF equalized pressure (the common
~ BELT'2
discharge and suction pressure that occurs after
several minutes) exceeds 965 kPa (140 psi),
02738-F which is a rare occurrence at high ambient
temperatures with a hot engine, turn A/C OFF for
a few seconds and then back ON after fan blade
DIAGNOSIS begins to cool Ale condenser core.
3. If any of the accessories are damaged, or have a
Inspectio"n and Verification worn or damaged bearing or internal torsional
resistance above normal for any reason. All of the
Drive Belt Cracking/Chunking/Wear accessories should be rotatable by hand in the
Under severe operating conditions (high unloaded condition. If any are not, the accessory
temperatures, low humidity), drive belt rib cracking should be inspected.
can occur at less than 96,000 km (60,000 miles). 4. If fluid gets on the drive belt. These would include
Drive belt rib cracking perpendicular to the belt ribs is power steering fluid, engine coolant, engine oil or
not a reason for concern and has no detrimental effect air conditioning system lubricant.
on belt performance. Cracks parallel to ribs are not If fluid does get on the drive belt during service,
acceptable. the best policy is to clean the drive belt with soap
Drive belt "chunking" is where the rubber material and water and thoroughly rinse with clean water.
actually chunks out between the cracks. The drive belt The drive belt does not have to be replaced if no
(8620) should be replaced if chunking occurs. apparent damage has occurred.

ALL RIGHTS RESERVED
DIAGNOSIS (Continued)
5. If drive belt is too long. A drive belt that is too long 6. If the drive belt tensioner is worn or damaged.
will allow the drive belt tensioner arm to go all the The drive belt tensioner arm should rotate freely
way to drive belt tensioner arm travel stop under without binding.
certain load conditions, which will untension the
drive belt. If the drive belt tensioner (68209) is
resting on the stop, replace the drive belt.
Symptom Chart
ACCESSORY DRIVE BELT DIAGNOSIS
• Excessive Noise/Belt Squeal • Seized accessory. • CHECK all accessories for free
rotation and REPLACE accessory
if necessary. REPLACE drive belt.
• Loose drive belt. • CHECK condition and tension of all
drive belt. REPLACE drive belt or
ADJUST tension of manually
tensioned drive belt as necessary.
• CHECK that automatic drive belt

tensioner is within the indicator
marks. CHECK for correct drive
belt length if drive belt tensioner is
out of operating range.
• Rattle • Loose pulley or accessory. • CHECK for looseness and tighten.
• Noisy Tensioner Pulley Bearing • Worn bearing. • REPLACE pulley per automatic
belt tensioner pulley replacement
procedure.
• Belt Chirp • Misaligned power steering pump

pulley.
• ALIGN power steering pump pulley
per power steering pump pulley
alignment procedure.
• Severe Belt Flutter • Loose drive belt. • CHECK belt tension and ADJUST
(manually tensioned belts only) if
necessary. CHECK condition of
drive belt and REPLACE if
necessary.
• Binding tensioner arm. • REMOVE drive belt from drive belt
tensioner and VERIFY that
tensioner arm is not frozen in
position or that arm does not bind
when manually moved throughout
its operating range.
• Frayed Drive Belt • Drive belt not seated correctly

(poly-V belt).
• REPLACE drive belt and VERIFY
correct belt seating.
• Severely misaligned pulley.
• USE a straightedge to CHECK for
severe angular misalignment
between adjacent pulleys.
CORRECT as necessary.
•• Tensioner pulley. • Replace tensioner.
••
Drive belt too tight. REPLACE drive belt.
• Drive belt worn out. REPLACE drive belt.
• Severely Glazed Drive Belt • Seized accessory. • CHECK all accessories for free
rotation and REPLACE if
necessary. REPLACE drive belt.
• Loose drive belt. • REPLACE drive belt.
• Improper Accessory Operation

(Power Steering or Air Conditioning
• Loose drive belt.
• CHECK drive belt for looseness or
GLAZING and REPLACE or
Doesn't Work, Engine Overheats or ADJUST tension of manually
Battery Doesn't Charge) tensioned belts if necessary.

ALL RIGHTS RESERVED
ACCESSORY DRIVE BELT DIAGNOSIS (Continued)

• Drive Belt Jumps off Pulley • Greatly misaligned pulleys. • CHECK for misalignment between
adjacent pulleys.
• Drive belt not seated correctly
(poly-V belt).
• REPLACE drive belt and VERIFY
correct seating.
• Pulley wobble. • VERIFY that no pulley wobbles
during engine operation.
Conditions causing wobble are:
bent pulley, bent accessory shaft,
rear face of pulley not seated flat
against mating surface.
• Excessive crankshaft end play. • Engine REBUILD.
• Excessive Wear on Drive Belt

Tensioner.
• Extended off-road operation. • REPLACE drive belt tensioner per
automatic belt tensioner pulley
replacement procedure.
j '\
Component Tests Belt Length Indicator, 4.9L MFI
Drive Belt Tension
BELT LENGTH
~
Check drive belt tension as described in this section. If INDICATOR
tension is not within specification, check drive belt IE;; MAXIMUM
tensioner (68209). Service components as required. MINIMUM ACCEPTABLE
ACCEPTABLE ~ MARK
Drive Belt Tensioner, Automatic MARK \I II
The drive belt tensioner will maintain correct belt
tension if the correct length drive belt (8620) is on the
engine (6007). To verify that the drive belt tensioner is INDICATOR SHOULD BE BETWEEN MARKS
working properly on the 4.9l, 7.3l and 7.5l, check to
see that the belt length indicator mark on the drive belt
tensioner is between the maximum and minimum
marks. The 5.0l and 5.8l drive belt tensioners do not
have belt length indicator marks.
USE PULLEY
BOLT ONLY
TO RELIEVE
BELT TENSION
DRIVE BELT TENSIONER-68209

4.9 MFI Q2739-E
This belt system has a drive belt tensioner that can be

misinstalled if the pivot bolt is cross-threaded in the
generator mounting bracket (10153) or bent. This can
result in an out-of-sheave line condition of the belt idler
pulley (8678).
1. Check that the end of the tensioner spring is
looped around the spring stop in the generator
mounting bracket and can provide the 60 pound
nominal output (± 15%).

ALL RIGHTS RESERVED
2. Check that the routing idler bolt is not cross Belt Length Indicator, 7.5L MFI
threaded and is tightened to 46-63 N·m (34-46
Ib-ft). BELT LENGTH
INDICATOR
3. Check that both the drive belt tensioner and belt
idler pulley are parallel to each other and the MAXIMUM
sheave line. ACCEPTABLE
MARK
---le!!~~~ ......- MINIMUM
ACCEPTABLE
MARK
INDICATOR SHOULD BE BETWEEN MARKS
USE PULLEY
BOLT ONLY
TO RELIEVE
QAOIO-A BELT TENSION
Part
1 10300 Generator
3 - Air Conditioner Pulley
(Part of 190629)
5 8509 Water Pump Pulley DRIVE BELT TENSIONER·8B209
7.5MFI Q2741-e
6 6312 Crankshaft Pulley
7 98447 Secondary Air Injection
Pump Pulley Belt Length Indicator, F-Super Duty Motorhome
8 6B209 Drive Belt Tensioner Chassis, 7.5L MFI
1 PERCENT BELT STRETCH

INDICATOR - REPLACE BELT
USE BOLT TO LIFT TENSIONER

TO RELEASE BELT TENSION
Q3872·A
The belt tension can be checked as follows:

ALL RIGHTS RESERVED
4. Install a closed-end wrench on the tensioner Belt Length Indicator, 7.3L Diesel Engine
pulley bolt and rotate the tensioner arm to relieve
all tension from the drive belt. Slowly return arm
to rest against the drive belt and measure belt
tension using Rotunda Belt Tension Gauge
021-00019 or equivalent.
5. Rotate arm against drive belt causing the drive
belt tensioner to deflect approximately 12.7mm
(1 / 2 inch) from its rest position. Slowly release
tension from arm and measure belt tension.
6. Average the two tensions and verify that result is
above the minimum tension shown in the Drive
Belt Specifications chart.
USE BOLT TO LIFT TENSIONER

TO RELEASE BELT TENSION Q4083-A
Belt Tension Check
WATER
PUMP
WITH AIC ALT
/
/
AIR
PUMP / /~" WITHOUT Ale
CRANK-
4.9l DRIVE BELT SHAFT
IDLER
7.3L 01 TURBOCHARGED DIESEL DRIVE BELT
AIR
PUMP
S.Ol AND s.al DRIVE BELT WATER

0"",.. . .
tALT ....,
PUMP
,
PUMP'D
AIR '
' ....
",
CRANK-
SHAFT
7.Sl F-SUPER DUTY
MOTORHOME CHASSIS
7.Sl DRIVE BELT DRIVE BELT
Q4732-A

ALL RIGHTS RESERVED
Drive Belt Misalignment • Check all accessories, mounting brackets and drive
CAUTION: Incorrect drive belt installation will belt tensioner for any interference that would
cause excessive drive belt wear and may cause prevent the component from mounting properly.
the drive belt to come off the drive pulleys. Correct any interference condition and recheck belt
tracking.
NOTE: Original equipment drive belts are made of a
special cord construction and are subjected to special • lighten all accessories mounting brackets and drive
testing before they are approved for use. belt tensioner retaining hardware to specification.
Recheck drive belt tracking.
Replacement drive belts, other than O.E.M., may track
differently / improperly. If a replacement drive belt • Check drive belt tension as described in this
tracks improperly, the drive belt should be replaced section.
with an O.E.M. drive belt to avoid performance failure
or loss of drive belt during cold operation.
FACTORYINSTALLEO
POSITION IS FLUSH ± .010° Drive Belt Replacement
(.254MM)
Conditions requiring drive belt (8620) replacement are
~:a
~----
• rib chunk out, excessive wear, severe glazing, frayed
cords. Replace any drive belt exhibiting any of these
............ ;,,-- - conditions. Minor cracks in the ribbed side of
V-grooved portion of the drive belt are considered
acceptable.
Drive Belt Tensioner, Automatic
CRANKSHAFT PULLEY
6312 POWER STEERING PULLEY 1. Install a closed-end wrench on the tensioner
30673 pulley bolt and lift the tensioner arm away from
QAOI1-A
the drive belt.
Wit~ ~he engine r~nning, check drive belt tracking (the 2. Remove old drive belt. Release drive belt
position of the drive belt on the drive belt tensioner. If tensioner (68209) slowly. Do not allow drive belt
the edge of the drive belt rides beyond the edge of the tensioner to snap back after the drive belt is
drive belt tensioner, this can cause noise and removed because this may damage the drive belt
premature wear. If a drive belt tracking condition tensioner.
exists, visually check the drive belt tensioner for
damage, especially the mounting pad surface. If the 3. CAUTION: Make sure the drive belt is
drive belt tensioner is not installed correctly with the properly seated on all pulleys. One
locating pins in the locating holes, the mounting revolution of the engine (6007) with an
surface pad will be out of position. This will result in incorrectly seated drive belt may snap
drive belt tension and chirp and squeal noises. tensile members in the drive belt.
If the above procedures do not correct the drive belt Install new drive belt over pulleys making sure
noise, try replacing the drive belt with a known good that all belt ribs are correctly seated in the pulley
original equipment drive belt. However, the drive belt grooves.
noise may return again (with mileage) if one of the
above conditions still exists uncorrected.
• With engine running, visually observe the grooves in
the pulleys (not the pulley flanges) for excessive
wobble. Replace components as required.
ALL RIGHTS RESERVED
Poly-V Belt Alignment 2. Remove old drive belt.

3. Install new drive belt and tension as described in
this section.
Accessory Drive Belt Tension Check, 7.5L MFI

Engine
f!fI/III
VIEW A
CORRECTED CONDITION
SIDE VIEWS!>F aE1.T -®
~3
® VIEW A
VIEWS
Q2764-E
Part
Description Part
Item Number
1 - Low Contact No Wear / Shine
1 8620 Belt Drive
(Part of 8620)
2 - High Pressure High 2 381649-S36 Bolt
Wear / Shine (Part of 8620) 3 389483-S36 Bolt
3 - Full Width (Part of 8620) 4 021-00019 Belt Tension Gauge
4 - Uniformly Dull Surface A - Tension Range
(Part of 8620) 711.6-889.6 N·m
5 - Bevel (Part of 8620) (160-200 Lbs.)
6 - Shiny Surface (Part of 8620) B - Tighten to 41-54 N·m
(30-40 Lb-Ft)
Manually Tensioned Belts C - Tighten to 54-71 N·m
(40-53 Lb·Ft)
1. Loosen generator adjustment bolts and pivot bolt
as shown in the following illustration.

ALL RIGHTS RESERVED
Automatic Tensioner Using a 16mm closed end wrench, remove the drive
belt according to the Drive Belt Tensioner, Automatic
removal procedure in this section.
NOTE: 7.5L (not F-Super Duty Motorhome Chassis)
bolts have a left-hand thread, requiring clockwise
motion to loosen. 4.9L and 7.5L F-Super Duty
Motorhome Chassis idler pulley bolts have a
conventional right-hand thread which loosens
counterclockwise.
1. NOTE: Excessive rearward force on the bolt
NOTE: LOCATING PIN MUST BE IN BRACKET during removal may over-stress and crack the
HOLE PRIOR TO TIGHTENING OF tensioner arm.
TENSIONER MOUNTING BOLT.
02765·D NOTE: Pulleys being replaced for suspected
bearing wear should be evaluated for rough
bearings. Bearing noise which continues or
Engine N·m Lb-Ft rapidly returns after a replacement pulley is
68-92 50-68
installed is usually belt chirp rather than worn
4.9l,7.5l
bearings. Bearings should rotate smoothly with a
5.0l, 5.8l, 7.3l 47-63 35-46 slight resistance due to the permanent
lubrication.
Belt Tensioner, 7.5L F-Super Duty Motorhome
Using the 16mm wrench, loosen the belt idler
Chassis
pulley retention bolt or nut.
NOTE: LOCATING PIN MUST BE IN BRACKET 2. Remove bolt or nut and dust shield and remove
HOLE PRIOR TO TIGHTENING OF
- TENSIONER MOUNTING BOLT. the drive belt tensioner (6B209) from the
tensioner arm locating boss.
3. Replace the pulley and reverse the removal
instructions observing the correct rotation of the
retention bolt.Tighten bolt or nut to specifications.
Fan and Clutch, 4.9L MFI

Fan Clutch Holding Tool T84T-6312-C
Q3673·A Fan Clutch Nut Wrench T93T 6312-B
Removal
1. Remove the fan shroud (8146). Refer to Section
Belt Tensioner Pulley Replacement 03-03.
2. CAUTION: The large clutch assembly nut has
Replacement a right-hand thread and must be rotated
Engine Tensloner Pulley counterclockwise to remove it.
4.9l/7.5l E7TA-6B209-HB E9TA-19A216-BA Remove the fan clutch (8A616) from the water
E7TA-6B209-CB pump (8501) by turning the large nut, which is
E7TA-6B209-FC part of the fan clutch, using Fan Clutch Holding
Tool T84T-6312-C and Fan Clutch Nut Wrench
Conditions requiring pulley replacement are excessive T93T-6312-B.
pulley wear or pulley bearing noise usually resulting
from extended operation in abrasive off-road 3. Remove the fan blade (8600) and fan clutch.
conditions.

ALL RIGHTS RESERVED
4. If the fan blade and fan clutch have to be 3. Pull fan clutch (8A616) and fan blade (8600) off
separated, remove the remaining bolts attaching water pump pilot and remove assembly from
the fan blade to the fan clutch. vehicle.
4. Remove four screws and separate fan clutch
from fan blade.
Installation
1. Position fan blade to fan clutch and attach with
four screws. lighten screws to 16-24 N·m (12-18
Ib-ft).
2. Position fan blade and fan clutch to water pump
pulley (8509) and attach with four screws.
Tighten screws to 16-24 N·m (12-18Ib-ft).
3. Install the fan shroud. Refer to Section 03-03.
Part
2 8600 Fan Blade
3 8A616 Fan Clutch
4 57632-S2 Screws (4)
A - Tighten to 53-72 N·m Part
(39-53 Lb-Ft)
(12-18 Lb-Ft) 1 8509 Water Pump Pulley
2 57632-S Screw and W,asher
Installation Assembly, 5/ 16-18 x .62
Hex
1. Install all of the bolts attaching the fan blade to Fan Blade (5.0 and 5.al)
3 8600
the fan clutch. lighten all bolts to 16-24 N·m
( 12-18Ib-ft). 4 8600 Fan Blade (7.5l)
5 8A616 Fan Clutch
2. CAUTION: The clutch assembly nut has a 6 380288-S2 Screw and Washer
right-hand thread and must be rotated Assembly. 5/ 16-24 x .88
clockwise to tighten it. Hex
Install the fan blade / fan clutch on the water pump A - Tighten to 16-24 N·m
hub by turning the large nut, which is part of the (12-18 Lb-Ft)
clutch, using Fan Clutch Holding Tool
T84T-6312-C and Fan Clutch Nut Wrench
T93T-6312-B.
3. Install the fan shroud. Refer to Section 03-03. Fan and Clutch, 7.3l Diesel
SPECIAL SERVICE TOOL(S) REQUIRED '~
........
Description ( Tool Number
Fan and Clutch, S.Ol, S.8l and 7.Sl Engines Fan Clutch Nut Wrench \, "
T83T-6312-B ~
Removal Fan Clutch Pulley Holder " ,T94T-6312-AH
1. Remove fan shroud (8146) and radiator (8005) if
necessary. Refer to Section 03-03. Removal ~
1. Partially drain the engine cooling system~-----
2. Remove four screws retaining clutch on water
pump hub. 2. Remove the upper radiator hose (8260).
ALL RIGHTS RESERVED
3. Disconnect the coolant reservoir hose at radiator. 5. Remove the fan shroud screws.
4. CAUTION: Right-hand thread. Remove by 6. Remove the fan shroud and fan clutch.
turning nut counterclockwise. 7. Remove the bolts attaching the fan blade (8600)
Remove the fan clutch (8A616) using Fan Clutch to the fan clutch.
Nut Wrench 1831-6312-8 and Fan Clutch Pulley
Holder T941-6312-AH, set fan clutch in fan Installation
shroud (8146). 1. Install the bolts attaching the fan blade to the fan
clutch. Tighten to 16-24 N·m (12-18Ib-ft).
2. Install the fan shroud, and fan clutch.
FAN CLUTCH 3. Install the radiator fan shroud screws.
NUT WRENCH 4. CAUTION: Right-hand thread. Install by
T83T-6312-B
turning nut clockwise.
Install the fan clutch using Fan Clutch Nut Wrench
T831-6312-8 and Fan Clutch Pulley Holder
T94T-6312-AH. Tighten to 113-153 N·m (84-112
Ib-ft).
A23072-A

ALL RIGHTS RESERVED
~ Fan Blade and Clutch Assembly 7.3L, Diesel
FAN
NOTE: RIGHT HAND THREAD CLUTCH
8A616
NOTE: RIGHT
HAND
THREAD
FAN SCREW AND

CLUTCH WASHER ASSEMBLY
8A616 VlEWZ
57633-8410
Q4238-A
5. Install the coolant reservoir hose to radiator. 5. Tighten adjustment bolt to specification while
6. Install the upper upper radiator hose. maintaining belt tension. Refer to illustration for
torque specification.
7. Refill and bleed the engine cooling system. Refer
to Section 03-03. 6. Tighten pivot bolt to specification. Refer to
illustration for torque specification.
7. Check and readjust belt tension if necessary.
ADJUSTMENTS 8. Start engine and idle for 5 minutes.
9. Recheck belt tension.
Drive Belt Tension Adjustment, Manually 10. If tension is less than the minimum tension after 5
Tensioned Belts, 7.5L Gasoline Engine minutes operation from the table, then reset belt
1. Use Rotunda Belt Tension Gauge 021-00019 or tension to within used belt tension limits. Start
equivalent for checking tension. engine and idle for 5 minutes. Recheck belt
tension.
2. Loosen generator adjustment bolts.
3. Tighten pivot bolt enough to remove all free play
from pivot area but not enough to prevent the
generator (GEN)(10300) from rotating to allow
belt tensioning.
4. Place an adjustable wrench on the top lug of the
generator and rotate generator until the drive belt
(8620) is tightened to the proper tension.
Be sure to use the new belt tension for new drive
belts and the used belt tension for used drive
belts. A used drive belt is one with more than 5
minutes of engine (6007) operation. See Drive
Belt Specifications chart in the Specifications
portion of this section.
ALL RIGHTS RESERVED
11. If belt will not hold tension, then replace drive belt. Power Steering Pulley Alignment
Steering Pump Pulley Remover T69L-10300-B
Steering Pump Pulley Replacer T65P-3A733-C
A chirping noise from the accessory drive belt that is

more noticeable at idle than at higher speeds may be
caused by a power steering pump pulley (3A733) that
is out of alignment.
The misaligned power steering pulley causes the
accessory drive belt to chirp as the belt enters it on an
angle on 4.9l engines, or after if leaves the power
steering pump pulley , travels over the water pump
pulley (8509) and enters into the crankshaft pulley
(6312) on an angle on 5.0l and 5.al engines. Verify
that the chirping noise is coming from the entrance to
one of these two pulleys by listening through a length
of rubber hose or other type of stethoscope-like
device.
If the chirp has been isolated to one of these pulleys,
then to correct this condition align the power steering
pump pulley using the following service procedure.
NOTE: Accessory drive belt chirp not corrected by
this procedure may be caused by a damaged pulley or
bent accessory shafts. Steady pulsation of the drive
belt tensioner (68209) indicates this condition.
Observe each pulley in the system for runout.
1. CAUTION: Do not sand the edges of the drive
belt or apply lubricants or dressings. These
are only temporary fixes and may damage
belt.
Q2764-E Clean the accessory drive belt with mild soap and
water to wash away oil or other contaminants.
Part 2. On some models, it may be necessary to remove
Item Number Description the fan shroud (8146) to allow for proper
1 8620 Drive Belt installation and operation of the power steering
pulley puller and installer tools.
2 390785-S36 Screw
3 391319-S2 Bolt 3. Using Steering Pump Pulley Remover
4 021-00019 Belt Tension Gauge T69l-10300-8 and Steering Pump Pulley
A - Belt Tension Range Replacer T65P-3A733-C set the power steering
711.6-889.6 N·m pump pulley hub to within ±.010 inch of being
(160-200 Lb.) flush with the end of the power steering pump
B - Tighten to 40-55 N·m shaft.
(30-41 Lb-Ft) 4. CAUTION: Damaged accessory drive belts
C - Tighten to 54- 71 N·m should be replaced before proceeding to
(40-53 Lb-Ft) Step 4. Only use a closed-end wrench to lift
the drive belt tensioner to avoid possible
damage. A wedged screwdriver will crack
the pulley or the housing.
Drive Belt Tension Adjustment, Automatically Operate the engine at idle for five (5) minutes to
Tensioned Belts see if chirping noise has been corrected. If not,
The drive belt tensioner (68209) has no provision for proceed to Step 5.
adjustment and will be damaged if forced to travel
beyond its operating range.

ALL RIGHTS RESERVED
5. Select a direction and move the power steering 6. Reinstall the fan shroud.
pump pulley at .50mm (.020 inch) increments in
that direction. After each move (increment),
remove the tool and operate the engine for five
(5) minutes. If chirp fades, alignment is being
achieved; if chirp increases, reverse the
alignment direction. Continue moving the pulley
until the noise is eliminated.
SPECIFICATIONS
DRIVE BELT SPECIFICATIONS

Used Belt Tension
Tensioning New Belt Tension (Greater Than 5 Min. Min. Tension After 5
Engine Method Belt Type (0 Min. Operation) Operation) Min. Operation
4.9l Automatic 6K poly-V Belt Tension OK if Tensioner Same as New Same as New
Within Indicator Marks.
95A 520 N (117 lb.) Min.
5.0l Automatic 6K poly-V Belt Tension OK if Tensioner Same as New Same as New
5.8l Within Indicator Marks.
227 N (51 lb.) Min.
7.5l (A/C & PIS Belt) 6K poly-V Belt Tension OK if Tensioner Same as New Same as New
Automatic Within Indicator Marks.
418 N (94 lb.) Min.
7.5l (Alt. & Air Pump 6K poly-V Belt 800-889 N (180-200 lb.) 489-578 N (110-130 lb.) 467 N (105 lb.)
Belt) Manual
7.3l Automatic 6K poly-V Belt 378 N (85 lb.) Min. Same as New Same as New

Description N·m Lb-Ft SPECIAL SERVICE TOOLS REQUIRED
Pivot Bolt. Alternator. 7.5l. All 54-71 40-53 Tool Number/
Adjuster Bolt, Alternator. 7.5l 41-54 30-40 Description illustration
Bolt, Automatic 68-92 50-68 T65P-3A733-C
~
Tensioner-to-Bracket, 4.9l, 7.5l Steering Pump Pulley Replacer
Bolt, Automatic 47-63 35-46

Tensioner-to-Bracket, 5.0l, 5.8l,
7.3l Diesel TIIP-3A733-C
Screw, Fan-to-Clutch, 4.9l, 5.0l, 16-24 12-18

T69l-1 0300-B
5.8l,7.5l
©fP6~
Steering Pump Pulley Remover
Clutch-to-Water Pump, 4.9l 53-72 39-53
Screw, Clutch-to-Water Pump, 16-24 12-18
5.0l. 5.8l, 7.5l T. . .1......
Screw, Clutch-to-Water Pump, 113-153 84-112
7.3l T83T-6312-B
~
Fan Clutch Nut Wrench
TI3T~12"
(Continued)
ALL RIGHTS RESERVED

(Continued)
SPECIAL SERVICE TOOLS REQUIRED (Cont'd) ROTUNDA EQUIPMENT

Tool Number/ Model Description
021-00019 Belt Tension Gauge
T84T-6312-C
Fan Clutch Holding Tool
T84T-I312-e
T94T-6312-AH
Fan Clutch Pulley Holder

ALL RIGHTS RESERVED
03-06A-1 Starting System, Gasoline Engines 03-06A-1
SECTION 03·06A Starting System, Gasoline Engines

VEHICLE APPLICATION ..................................•........03-06A-1 DISASSEMBLY AND ASSEMBLY (Cont'd.)
DESCRIPTION AND OPERATION Bushings .•...•............................................•...•....03-06A-12
Sequence of Operation 03-06A-2 Starter Drive Replacement. •.•..........................•..03-o6A-12
Starter System .••••••...............................•.......•.•...03-06A-1 Starter Motor.................................••.•.•.•............03-o6A-10
DIAGNOSIS AND TESTING SERVICE PROCEDURES .
Component Tests ............................................•...03-06A-6 Jump Starting ............•••••....•............•..........•......03-o6A-13
Armature•.•.............•.•................•..................•...03-06A-9 Road Service ....................................•.•..............03-06A-12
Starter 03-06A-6 CLEANING AND INSPECTION
Starter Solenoid .............•.................................03-06A-9 Armature Coil, Starter Motor ........•.....................03-o6A-14
Electrical Schematics •.••......................................03-06A-3 Bushings .............................•....•.•••.•.••.••............03-06A-14
Pinpoint Tests ...............................•.....................03-06A-5 Starter Drive and Flywheel Ring Gear.......•.........03-06A-14
Symptom Chart .............•..................•.....•............03-06A-4 Starter Frame and Magnet ...•••.••...•..........•.........03-06A-14
REMOVAL AND INSTALLATION SPECIFICATIONS ..........................•.•.••..•..........•....03-06A-15
Starter Motor..............•.....................•..•.............03-06A-10 SPECIAL SERVICE TOOLS/EQUIPMENT 03-o6A-15
DISASSEMBLY AND ASSEMBLY
Armature Replacement, Starter Motor 03-o6A-12
VEHICLE APPLICATION
F-Series Equipped with Gasoline Engines and Bronco
Starter System
The function of the starting system is to crank the
engine at a speed fast enough to permit the engine to
start. Heavy cables, connectors, and switches are
used in the starting system because of the large
current required by the starter motor (11001) while it
is cranking the engine. The amount of resistance in the
starting circuit must be kept to an absolute minimum to
provide maximum current for proper operation. A
discharged or damaged battery, loose or corroded
connections, or partially broken cables will result in
slower than normal cranking speeds, and may even
STARTER MOTOR ASSY
prevent the starter motor from cranking the engine. 11001
In case of starting system concern, the operator may J3406-A
have discharged the battery before calling for
assistance. A road service procedure is presented to Vehicles equipped with an automatic transmission
aid the service technician in such cases of starting have a park / neutral position (PNP) switch or
concern. Be sure to follow diagnosis procedures in the transmission range (TRS) sensor in the control circuit,
Powertrain Control/Emissions Diagnosis Manual 1, in which prevents operation of the starter motor unless
order to locate the cause of the starting difficulty. the selector lever is in the NEUT~AL or PARK position.
Road service is not a part of the diagnosis procedures.
Vehicles equipped with a manual transmission have a
The starting system includes the permanent magnet clutch pedal position switch in the control circuit that
gear-reduction starter motor with a solenoid-actuated prevents operation of the starter motor if the clutch
drive, the battery, a remote-control starter switch pedal is not fully depressed.
(part of the ignition switch (11572», the park / neutral
position switch or transmission range sensor (TRS)
(automatic transmission), the clutch pedal position
switch (CPP)( 11 A 152) (manual transmission), the
starter relay, and heavy circuit wiring.

ALL RIGHTS RESERVED
Sequence of Operation 6. The current flows to the starter motor, and the
drive pinion gear cranks the flywheel ring gear
1. The ignition switch (11572) is turned to the
and the engine crankshaft.
START position.
2. A fender-mounted starter relay is energized, 7. As current flows to the starter motor, the solenoid
which provides voltage to the starter solenoid pull-in coil is bypassed.
(11390). The starter solenoid is energized, 8. The hold-in coil keeps the drive pinion gear
creating a magnetic field in the coil. engaged with the flywheel ring gear.
3. The iron plunger core is drawn into the solenoid 9. The gear remains engaged until the ignition
coil. switch is released from the START position.
4. A lever connected to the starter drive (11350) A starter drive protects the starter motor from
engages the drive pinion gear to the flywheel ring excessive speeds during the brief period before the
gear (6384). driver releases the ignition switch from the START
5. When the iron plunger core is all the way into the position (as the engine starts).
coil, its contact disc closes the circuit between
the battery and the terminals of the starter motor
(11001).

ALL RIGHTS RESERVED
Electrical Schematics
Starter Motor Circuit, F-Series and Bronco
HOT AT ALL TIMES

See EVTM for more
IGNITION details of this circuit
SWITCH
F-SERIES
AND
BRONCO
IC60RI
I GASOLINE I
AOD
32 RlLB 32 RlLB
32" R/LB
32 RlLB 32 RlLB
TRANSMISSION
RANGE
SENSOR
32 RlLB
R
BATTERY R
STARTER
.---- IGNITION
SYSTEM
MOTORI
SOLENOID
BK
J5361-C

ALL RIGHTS RESERVED
Pin
Number Circuit Circuit Function
A4 687 Accessory Feed
(GV IV)
11 16(R/LG) Ignition Switch to Ignition Coil
Battery Terminal
12 - Not Used
GND - Not Used
P1 - Not Used
P2 - Not Used

CAUTION: When disconnecting the plastic
hardshell connector at the solenoid S-terminal,
grasp the plastic connector and pull lead off. DO
NOT pull separately on lead wire.
WARNING: WHEN SERVICING STARTER MOTOR
IGNITION SWITCH CONNECTOR (11001) OR PERFORMING OTHER UNDERHOOD
WORK IN THE VICINITY OF THE STARTER
J583o-B MOTOR, BE AWARE THAT THE HEAVY GAUGE
BATTERY INPUT LEAD AT THE STARTER
Pin SOLENOID (11390) IS "ELECTRICALLY HOT" AT
Number Circuit Circuit Function ALL TIMES.
B1 37 (V) Battery to Load A PROTECTIVE CAP OR BOOT IS PROVIDED
OVER THIS TERMINAL THAT MUST BE REPLACED
B2 37 (V) Battery to Load
AFTER SERVICING. BE SURE TO DISCONNECT
B3 37 (V) Battery to Load BATTERY NEGATIVE CABLE BEFORE SERVICING
B4 37 (V) Battery to Load STARTER.
B5 37 (V) Battery to Load 1. Inspect starting system for loose connections.
A1 297 Accessory Feed from Ignition 2. If system does not operate properly, note
(BK/LG) Switch condition and continue diagnosis using the
A2 687 Accessory Feed Symptom Chart.
(GV IV)
WARNING: WHEN WORKING IN AREA OF THE
A3 687 Accessory Feed STARTER MOTOR, BE CAREFUL TO AVOID
(GV IV) TOUCHING HOT EXHAUST COMPONENTS.
57A 37 (R/LB) Starter Control
(Continued)
Symptom Chart
STARTING SYSTEM
Engine cranks slowly. •• Low battery.
Ground not secure.
• Go to Pinpoint Test A.
• Connections loose.
•• Inoperative starter motor.
Shorted fuse or ignition switch.
Engine does not crank. •• Low battery.
Open fuse.
• Go to Pinpoint Test B.
•• Open ignition switch.

Shorts to ground.
••
Fuel system.
Engine system.
• Inoperative starter motor.

ALL RIGHTS RESERVED
03·06A·5 Starting System, Gasoline Engines 03·06A·5
STARTING SYSTEM (Continued)

Unusual starter noise. • Starter mounting. • Go to .Pinpoint Test C.
• Ring gear tooth damage or
excessive ring gear runout.
• Inoperative starter motor.
• Inoperative components.
Pinpoint Tests
PINPOINT TEST A: ENGINE CRANKS SLOWLY
A1 I CHECK FOR VOLTAGE TO STARTER
NOTE: Hoist vehicle (if necessary) to access starter Ves ~ GOtoA2.
solenoid terminals. No ~ CHECK wire connections
between battery and
CAUTION: Remove plastic safety cap on starter starter solenoid and the
solenoid and disconnect hardshell connector at ground circuit for open or
solenoid S-terminal as described under Removal and short. RETEST system.
•• Check
Key off. Transmission in PARK or NEUTRAL.
for voltage between starter B+ terminal and
starter drive housing.
• Is voltage between 12-12.45 volts?
A2 I CHECK STARTER MOTOR
•• Key off. Transmission in PARK or NEUTRAL.
Connect one end of a jumper wire to the starter B+
Ves ~ CHECK connections from
ignition circuitry to
terminal and momentarily touch the other end of solenoid S-terminal for
solenoid S-terminal. open or short.
• Does starter motor crank? No ~ REPLACE starter motor
as outlined. RETEST
system.
PINPOINT TEST B: ENGINE DOES NOT CRANK

B1 I CHECK FOR VOLTAGE TO STARTER
NOTE: Hoist vehicle (if necessary) to access starter Ves ~ GOtoB2.
solenoid terminals. No ~ CHECK wire connections
between battery and
CAUTION: Remove plastic safety cap on starter starter solenoid. CHECK
solenoid and disconnect hardshell connector at ground connections at
solenoid S-terminal a8 described under Removal and battery to ground and
Installation in this section. starter solenoid to ground
for an open, short or
• NEUTRAL.
Ignition switches off. Transmission in PARK or security. If secure,
REFER to Section 14-00
• equivalent,
Using Rotunda Digital Volt-Ohmmeter 014-00407 or
check for voltage from starter B+
and CHECK battery
charge system.
terminal to starter drive housing (ground).
• Does voltmeter indicate 12 to 12.45 volts DC?
B2 I MANUALLV CRANK STARTER
~ CHECK connections from
• Ignition
NEUTRAL.
switches OFF. Transmission in PARK or Ves
ignition circuitry to
• terminal
Connect one end of a jumper wire to the starter B+
and momentarily touch the other end to
solenoid S-terminal for
open or short.
solenoid S-terminal. No ~ REPLACE starter motor.
• Does starter motor crank and crank quickly? REFER to Removal and
Installation. RETEST new
starter motor.

ALL RIGHTS RESERVED
PINPOINT TEST C: UNUSUAL STARTER NOISE

C1 I CHECK STARTER MOUNTING
• Check starter mounting to be flush, not cocked.
Check all connections to be secure. REFER to
Yes ~ GOtoC2.
No ~ SERVICE or REPLACE
Removal and Installation for mounting information. wiring or component
• Check other necessary components related to the
starting system to be securely mounted (ignition
mounting as required.
RETEST starting system
switch, regulator / distributor, battery and for noises.
transmission switches).
• Check wiring connection for damage or shorting due
to corrosion or stray wires.
• Are the starting system components and wiring
secure and undamaged?
C2 I CRANK ENGINE
• Put ignition switch in START then RUN position. As
engine is Ustarting" listen to individual components
Yes ~ REPLACE starter
solenoid.
for noise due to gear tooth damage, shorting, No ~ If noise is shorting or
sparking or knocking. sparking, CHECK for
• Is noise due to ring gear tooth damage? grounded feeds to
battery or starter motor.
If noise is knocking,
Component Tests 3. Stop cranking engine, and reduce resistance of

carbon pile until voltmeter indicates same reading
Starter as that obtained while starter motor cranked the
Load Test engine. The ammeter will indicate starter system
current draw under load. Check this with value
Conduct this test if the starter motor (11001) cranks
listed in the specifications in this section.
slowly and it is desired to compare current to
specifications.
1. Connect Rotunda Starting and Charging Tester
078-00005 or equivalent. Make sure that current
is not flowing through ammeter and heavy-duty
carbon pile rheostat portion of circuit (rheostat at
maximum counterclockwise position).
2. NOTE: Set parking brake.
Place transmission in NEUTRAL or PARK. Crank
engine with ignition switch (11572) off, and
determine exact reading on voltmeter. This test is
accomplished by disconnecting push-on
connector S at starter motor relay and
connecting a remote control starter switch from
positive battery terminal to S-terminal of starter
relay.

ALL RIGHTS RESERVED
Starter Motor Load Test
J5698-B
Part Part
1 - Negative Lead 5 - To Other Circuits
(Part of 078-00005) 6 11450 Starter Relay
2 - Voltmeter 7 078-00005 Rotunda Starting and
(Part of 078-00005) Charging Tester
3 - Ammeter 8 11390 Starter Solenoid
(Part of 078-00005) 9 11001 Starter Motor
4 - Positive Lead 10 10655 Battery
(Part of 078-00005)
11 11572 Ignition Switch
(Continued)
Voltage Drop Tests 3. Connect Rotunda Digital Volt-Ohmmeter

If the starter motor cranks slowly and the battery 014-00407 or equivalent positive lead to the
(10655) is satisfactory, there may be a malfunction of . battery positive ( +) post. Connect Rotunda
the starter motor or in the cranking circuit wiring. To Digital Volt-Ohmmeter 014-00407 or equivalent
determine if the problem is in the wiring, a voltage drop negative lead to the solenoid M-terminal.
test must be performed. 4. Engage the remote starter switch. Read and
These tests are performed to determine if there is . record the voltage. The voltage reading should be
excessive resistance in the starter motor circuit. 0.5 volt or less.
Always make the volt-ohmmeter connections at the 5. If the voltage reading is higher than this,
component terminal rather than at the cable wiring end indicating excessive resistance, move the
connector. Making a connection at the wiring end Rotunda Digital Volt-Ohmmeter 014-00407 or
connector could result in false readings because the equivalent negative lead to the starter solenoid
meter will not pick up a high resistance between the B-terminal and repeat the test. If the voltage
wiring connector and the component. reading at the B-terminal is lower than 0.5 volt,
the concern is either in the connections at the
Motor Feed Circuit solenoid or in the solenoid contacts.
1. Prevent the engine from starting by disconnecting
the ignition coil (12029).
2. Connect a remote starter switch between the
starter solenoid S-terminal and the battery
positive (+) terminal.

ALL RIGHTS RESERVED
6. Remove the cables from solenoid B-, S-, and 2. Connect a remote starter switch between the
M-terminals. Clean the cables and connections starter solenoid S-terminal and the battery
and reinstall the cables to the proper terminals. positive (+) terminal.
Repeat Steps 1 through 5 above. If the voltage 3. Connect a Rotunda Digital Volt-Ohmmeter
drop reading is still higher than 0.5 volts when 014-00407 or equivalent positive lead to the
checked at the M-terminal or lower when starter motor housing (connection must be clean
checked at the B-terminal, the concern is in the and free of rust or grease). Connect Rotunda
solenoid contacts. Remove and replace the Digital Volt-Ohmmeter 014-00407 or equivalent
starter motor ( 11002) or starter solenoid negative lead to the negative (-) battery terminal.
(11390), if available.
4. Engage the remote starter switch and crank the
7. If the voltage reading taken at the starter solenoid engine. Read and record the volt-ohmmeter
B-terminal is still higher than 0.5 volt after reading. The reading should be 0.2 volt or less.
cleaning the cables and connections at the
starter solenoid, the concern is eitt,er in the 5. If the voltage drop is more than 0.2 volt, clean the
positive (+) battery cable connection, or in the negative cable connections at the battery and
positive battery cable itself. body connections, and retest. If the voltage drop
is still too high, perform the following test:
8. By moving the Rotunda Digital Volt-Ohmmeter
014-00407 or equivalent negative lead toward
the battery and checking each mechanical Voltage Drop Motor Feed Circuit
connection point, the excessive voltage drop can
be located. When the high reading disappears,
the last mechanical point that was checked is the
concern.
Voltage Drop Motor Feed Circuit
J6271·A
Part
1 - S-Terminal (Part of 11001)
J6270-A 2 - B-Terminal (Part of 11001)
3 - Remote Starter Switch
4 014-00407 Rotunda Digital
Part Volt-Ohmmeter
Item Number Description 5 - M-Terminal (Part of 11001)
1 - S-Terminal (Part of 11001)
Individual Cable
2 - B-Terminal (Part of 11001)
3 - Remote Starter Switch The resistance of any cable can be checked in the
4 014-00407 Rotunda Digital same manner by using Rotunda Digital Volt-Ohmmeter
Volt-Ohmmeter 014-00407 or equivalent.
5 - M-Terminal (Part of 11001) 1. Determine which way the current is flowing in the
cable. Connect Rotunda Digital Volt-Ohmmeter
Motor Ground Circuit 014-00407 or equivalent positive lead to the end
A slow cranking condition can be caused by of the cable nearest battery positive.
resistance in the ground or return portion of the 2. Connect Rotunda Digital Volt-Ohmmeter
cranking circuit. Check the voltage drop in the ground 014-00407 or equivalent negative lead to the
circuit as follows: terminal at the other end of the cable.
1. Prevent the engine from starting by disconnecting
the ignition coil.

ALL RIGHTS RESERVED
3. Crank the engine and observe Rotunda Digital

Volt-Ohmmeter 014-00407 or equivalent. The
voltage reading should be 0.2 volt or lower. If the
voltage drop is too high, clean the terminal ends.
Retest, and if still high, replace the cable.
Motor Pinion Test
Turn the starter drive pinion by hand and hold the
overrunning clutch. Replace the starter drive (11350)
if the pinion turns in both directions or does not turn.
COMMUTATOR
Starter Solenoid
Make sure that the starter solenoid is isolated
electrically from the starter motor. Using Rotunda
Digital Volt-Ohmmeter 014-00407 or equivalent,
check for cOl1tinuity between S-terminal and
M-terminal, and between S-terminal and ground
(frame). If there is no continuity the following
PINION conditions may exist:
J4581-A • open wire; replace starter solenoid.
• ice, dirt or other foreign material preventing contact.
No-Load Test
The starter no-load test will uncover such conditions
as open or shorted windings, or rubbing starter motor
armature ( 11005). The starter motor can be tested at
no-load on the test bench only.
NOTE: A remote control starter switch should be used
in the S-circuit for turning the starter motor ON and
OFF during testing.
Armature
Open Circuit Test
An open circuit starter motor armature may
sometimes be detected by examining the commutator STARTER MOTOR ASSY
for evidence of burning. A burn spot on the 11001
J3406-A
commutator is caused by an arc formed every time the
commutator segment, connected to the open circuit
winding, passes under a brush. Solenoid S-Terminal Circuit Resistance
Grounded Circuit Test 1. Using Rotunda Digital Volt-Ohmmeter 014-00407
This test will determine if~the winding insulation has or equivalent, check the resistance of the entire
been damaged, permitting a conductor to touch the S-terminal circuit, including all the switches,
frame or core. To determine if the windings are wires, and connections. Resistance should be
grounded, touch one lead of Rotunda Digital less than 0.08 ohm.
Volt-Ohmmeter 014-00407 or equivalent to the 2. If resistance is more than 0.08 ohm, replace the
armature winding and the other lead to the starter solenoid.
commutator, as shown. Infinite resistance indicates a
normal condition. Solenoid M-Terminal
1. Using Rotunda Digital Volt-Ohmmeter 014-00407
or equivalent, check for continuity between the
solenoid M-terminal and the solenoid housing.

ALL RIGHTS RESERVED
03-06A-10 Starting System, Gasoline Engines 03-06A·10
2. If there is no continuity, replace the starter 3. Tighten the lower bolt to 20-27 N·m (15-20 Ib-ft).
solenoid. 4. Be sure that heat shield is properly positioned
over starter solenoid. Connect connector on
starter solenoid. Be careful to push straight on
and make sure connector locks in position with a
notable click or detent.
5. Install starter cable nut to starter terminal.
Tighten to 9-14 N·m (80-124 Ib-in).
6. Replace red safety cap.
7. Lower vehicle to floor.
8. Connect battery negative cable.
Starter Motor
J6272·A NOTE: Although disassembly and service procedures
are shown for the starter motor ( 11001) in this
section, the starter motor should be returned to Ford
Return Parts Center for analysis and review.
REMOVAL AND INSTALLATION Disassembly
1. Remove positive brush connector from
Starter Motor M-terminal.
Removal 2. Remove retaining screws and starter solenoid
WARNING: WHEN SERVICING STARTER MOTOR (11390).
(11001) OR PERFORMING ANY MAINTENANCE IN 3. Remove through-bolts and separate drive end
THE AREA OF THE STARTER MOTOR, NOTE THAT housing from starter frame. Remove housing seal
THE HEAVY GAUGE INPUT LEAD CONNECTED TO assembly from drive. Remove drive and gear
THE STARTER SOLENOID (11390) IS HOT AT ALL assembly from drive end housing.
TIMES. MAKE SURE THE PROTECTIVE CAP IS 4. Remove drive lever from starter drive (11350).
INSTALLED OVER THE TERMINAL AND IS Remove starter drive stop ring (11222) and stop
REPLACED AFTER SERVICE. ring retainer (11223) from driveshaft, then
1. NOTE: When the battery is disconnected and remove starter drive from shaft. Push E-ring off
reconnected, some abnormal drive symptoms driveshaft, and separate gear assembly from
may occur while the powertrain control module driveshaft.
(PCM)(12A650) relearns its adaptive strategy. 5. Remove brush plate screws and brush end plate
The vehicle may need to be driven 10 miles or and bushing (11049) from starter frame. Remove
more to relearn the strategy. brush holder ( 11061) and push starter motor
Disconnect the battery negative cable. armature ( 11005) out of frame.
2. Raise the vehicle on a hoist. Refer to Section Assembly
00-02.
NOTE: Use ESF-M 1C218-A Grease during assembly.
3. CAUTION: When disconnecting hardshell
connector at S-termlnal, grasp the plastic 1. Install starter motor armature in starter frame.
shell and pull off. Do not pull on wire. Be Apply a thin coating of ESF-M 1C218-A Grease or
careful to pull straight off to prevent damage equivalent low temperature grease on both ends
to the connector and S-termlnal. If any part of shaft and spline. Install brush holder making
of the connection Is damaged, replace the sure brushes fit over commutator. Apply grease
damaged components. to bearing bore in brush end plate and bushing.
Push back grommet onto frame and attach brush
Disconnect starter cable and push-on connector end with screws. Tighten to 2-3 N·m (18-27 Ib-in).
from starter solenoid.
2. Apply grease to driveshaft spline and place
4. Remove upper bolt. stationary gear assembly over driveshaft. Install
5. Remove lower bolt. pinion thrust washer (11036) and push E-ring
onto driveshaft. Place starter drive onto drive
Installation shaft and install starter drive stop ring and stop
1. Position starter motor to engine and install upper ring retainer. Attach drive lever to starter drive.
and lower bolt finger-tight. 3. Grease and install planet gears (11 K 190).
2. Tighten the upper bolt to 20-27 N·m (15-20 Ib-ft).

ALL RIGHTS RESERVED
03·06A·11 Starting System, Gasoline Engines 03-06A-11
4. Apply grease into drive end housing bearing bore 6. Position starter solenoid to housing making sure
(approximately one-quarter full). Install drive gear that plunger is attached through drive lever
assembly into housing, making sure to line up bolt (bottom terminal (M) should have a metal strip
holes in gear assembly and housing. Place gear attached to it). Tighten bolts to 5-10 N·m (45-89
retainer over gear assembly. Install housing seal Ib-in).
assembly into drive end housing. 7. Attach positive brush connector to starter
5. Position starter frame to housing and install solenoid (bottom terminal). Tighten nut to 9-14
through-bolts. Tighten to 5-10 N·m (45-891b-in). N·m (80-124Ib-in).
8. Check that no-load current draw is within
specification. Refer to the Component Tests in
this section.
Starter Motor, Exploded View
J5390-A
Part ~
Part
1 11001 Starter Motor 12 11070 Drive Letter
2 N805405 Solenoid Screws 13 N805404 Truarc E-Ring
3 11130 Drive End Housing 14 11036 Pinion Thrust Washer
4 11390 Starter Solenoid 15 11A 165 Stationary Gear
5 11A059 Solenoid Heat Shield 16 11K190 Planet Gear
6 N805403 Terminal Nut 17 11A 167 Planet Gear Retainer
7 11A171 Housing Seal Assembly 18 11A 172 Armature Thrust Ball
8 11135 Bushing 19 11005 Starter Motor Armature
9 11223 Stop Ring Retainer 20 11A 169 Magnet Retainer (6 Req'd)
10 11222 Starter Drive Stop Ring 21 11A 168 Magnet Pole Piece (6 Req'd)
11 11350 Starter Drive 22 11A161 Pole Shunt (6 Req'd)
ALL RIGHTS RESERVED
Part Part
23 11076 Starter Frame 26 11135 Bushing
24 11061 Brush Holder 27 11049 Brush End Plate and Bushing
25 11059 Brush Spring 28 N805406 Brush Plate Screw
(Continued) 29 N805428 Through-Bolt
Starter Drive Replacement 7. Attach positive brush connector to starter

1. Remove positive brush connector from solenoid (11390) (bottom terminal). lighten nut to
M-terminal. Remove retaining screws and remove 9-14 N·m (8Q-1241b-in).
starter solenoid (11390). 8. Check that no-load current draw is within
2. Remove through-bolts and separate motor specification. Refer to the Component Tests in
assembly drive end housing. Remove housing this section.
seal from drive end housing. Remove drive gear
assembly from housing and detach drive lever.
3. Remove starter drive stop ring (11222) and stop
ring retainer (11223) from driveshaft and then
Bushings
remove starter drive (11350). Disassembly and Assembly
4. Apply a thin coating of ESF-M 1C218-A Grease or 1. The bushings can be pressed or tapped out of
ec;uivalent low temperature grease on driveshaft their housing using a driver of the appropriate
spline. Install new drive gear assembly on size. Be sure the housing is well supported.
driveshaft. Install new starter drive stop ring and
2. Immerse new bushings in engine oil (SAE 30 or
stop ring retainer. Attach drive lever.
40) for at least 20 minutes before installation.
5. Partially fill drive end housing bearing bore with
3. NOTE: Do not ream the bushings after installation
grease (approximately one-quarter full). Install
since the self-lubricating qualities of the bushing
drive gear assembly in housing, making sure to
may be damaged.
line up bolt holes in gear assembly and housing.
Press or tap the new bushing into position using a
6. Install lever support and housing seal in drive end
driver.
housing.
7. Position starter frame to housing and install
through-bolts. lighten to 5-10 N·m (45-891b-in). BUSHING DRIVE END
(PART OF HOUSING
8. Install starter solenoid. Refer to Assembly. 11049) 11130
Armature Replacement, Starter Motor

1. Remove positive brush connector from
M-terminal.
2. Remove through-bolts and separate motor from
gear assembly and drive end housing.
3. Remove screws, brush end plate and bushing
(11049) and brush holder (11061) from starter BRUSH END BUSHING
frame. Remove starter motor armature (11005) PLATE AND 11135
from frame. BUSHING
11049 J3732·B
4. Install new starter motor armature in frame. Apply
a thin coating of ESF-M 1C218-A Grease or
equivalent low temperature grease on both ends
of driveshaft and pinion. SERVICE PROCEDURES
5. Install brush holder. Using tool, make sure that
brushes fit over commutator. Push black Road Service
grommet onto frame. Apply grease to bearing
bore in brush end plate and bushing and attach to For cases of a starter motor (11001) that cranks the
starter frame. engine very slowly, connect a 12-volt booster battery
to the system.
6. Position starter frame to gear assembly and drive
end housing and install through-bolts. lighten to
5-10 N·m (45-891b-in).

ALL RIGHTS RESERVED
03-06A-13 Starting System, Gasoline Engines 03·06A·13
Jump Starting A protective cap or boot is provided over this

terminal that must be replaced after servicing. Be
To avoid damage to the vehicle and battery or the
sure to disconnect battery negative cable before
possibility of personal harm, follow these instructions
servicing starter motor.
and precautions:
WARNING: HYDROGEN AND OXYGEN GASES ARE • Connect one end of second jumper cable to
battery negative voltage (-) terminal of booster
PRODUCED DURING NORMAL BATTERY
battery. Connect other end to an engine
OPERATION. THIS GAS MIXTURE CAN EXPLODE
bolthead or good metallic contact spot on
IF FLAMES, SPARKS OR LIGHTED TOBACCO ARE
engine of vehicle to be started, NOT TO
BROUGHT NEAR THE BATTERY. WHEN
BATTERY NEGATIVE VOLTAGE (-) BATTERY
CHARGING OR USING A BATTERY IN AN
TERMINAL.
ENCLOSED SPACE, ALWAYS PROVIDE
VENTILATION AND SHIELD YOUR EYES.
WARNING: KEEP OUT OF REACH OF CHILDREN.
BATTERIES CONTAIN SULFURIC ACID. AVOID
CONTACT WITH SKIN, EYES OR CLOTHING.
ALSO, SHIELD YOUR EYES WHEN WORKING
NEAR THE BATTERY TO PROTECT AGAINST
POSSIBLE SPLASHING OF THE ACID SOLUTION.
IN CASE OF ACID CONTACT WITH SKIN, EYES OR
CLOTHING, FLUSH IMMEDIATELY WITH WATER
FOR A MINIMUM OF FIFTEEN MINUTES. IF ACID IS
SWALLOWED, DRINK LARGE QUANTITIES OF
MILK OR WATER, FOLLOWED BY MILK OF
MAGNESIA, A BEATEN EGG, OR VEGETABLE OIL.
CALL A PHYSICIAN IMMEDIATELY. J2704-C
CAUTION: Do not disconnect the battery of the
vehicle to be started. Disconnecting the battery • Make sure jumper cables are not in way of
could damage the vehicle electronic system. moving engine parts.
Negative Grounded Battery • Start engine of vehicle with good battery. Run
WARNING: TO AVOID ANY POSSIBILITY OF engine at a moderate speed.
INJURY, USE PARTICULAR CARE WHEN • Start engine of vehicle with discharged
CONNECTING A BOOSTER BATTERY TO A battery. Follow starting instructions in the
DISCHARGED BATTERY. Owner Guide.
1. Position vehicles so jumper cables will reach, • Leave all switches off except blower motor.
being careful that vehicles do not touch. Reduce engine speed to idle on both vehicles
2. Turn on blower motor (18527) of vehicle to be to prevent possible damage to vehicle
started (set control on DEFROST for vehicles electrical systems.
equipped with automatic temperature control). 4. Remove jumper cables in exact REVERSE
Turn off other switches and lamps. sequence. Begin by removing jumper cable from
3. Make jumper cable connections. engine of vehicle that had discharged battery.
If the starter does nothing, jump the relay to attempt to
• Connect one end of first jumper cable to start engine.
battery positive voltage ( +) terminal of
discharged battery and other end to battery An assistant must remain in the driver's' seat while
positive voltage ( +) terminal of booster "jumping" the relay, or a remote switch should be
battery. used that allows the technician to remain in the driver's
seat while "jumping" the relay.
WARNING: MAKING THE FINAL CABLE
CONNECTION COULD CAUSE AN ELECTRICAL If the starter motor does not turn the engine over, even
SPARK NEAR THE BATTERY AND COULD CAUSE with the booster battery attached, refer to Symptom
AN EXPLOSION. REFER TO WARNINGS AT THE Chart in this section.
BEGINNING OF THE JUMP STARTING
PROCEDURE.
CAUTION: When servicing starter motor (11001)
or performing other underhood work in the
vicinity of the starter motor, be aware that the
heavy gauge battery input lead at the starter
solenoid (11390) is "electrically hot" at all times.
1995 F-150, F-250, F-350, Bronco, F-SuperDuty P,owertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
CLEANING AND INSPECTION
Armature Coil, Starter Motor

STARTER
CAUTION: Do not wash the drive because the FRAME
solvent will wash out the lubricant causing drive AND MAGNET
to slip. Use a bruch or compressed air to clean 11075
the drive, starter motor armature (11005), brush,
and gear assemblies, drive end housing, pole
pieces and planet gears (11 K190). Wash all other
parts In solvent and dry.
1. Inspect windings for broken or burned insulation
and unwelded or open connections.
2. Check starter motor armature for open circuits,
shorts and grounds. Check for pole rub or rub on
,magnetic shunts. J4577-B
3. Check commutator for runout. Inspect shaft and
two bearings for scoring and excessive wear with
Dial Indicator D87L-4201-A and Magnetic Base
D87L-4201-B or equivalent. If commutator is
rough, or more than o. 12mm (.005 inch) out of Starter Drive and Flywheel Ring Gear
round, it must be replaced. Inspection
1. CAUTION: The starter drive (11350) is
DIAL INDICATORIMAGNETIC BASE packed with grease and sealed, and should
D78P-4201-B
not be washed In solvent.
Examine gears, spline on output shaft (11355)
and drive pinion for chipped, broken or worn
conditions. Replace if required.
~
"'''~
:I,,,,, • Q)
:I",,,
"'I.
"''
NORMAL WEAR PATTERN SMALL WEAR PATTERN

"V" BLOCKS
COMMUTATOR RUNOUT CHECK J2711-F
MILLED CONDITION EXCESSIVE

WEAR ON 2 OR 3 TEETH
Bushings
1. Inspect the self-lubricating bronze / iron armature
bushings in the drive housing and brush end plate.
Replace bushings whenever excessive starter
motor armature shaft side-play is evident
(maximum allowable 0.2mm [0.008 inch]).
2. Replace bushings if worn or scored. Check the MILLED GEARS
armature shaft for wear if the bushings are J2713-B
excessively scored or 'worn. Service or replace
starter motor armature (11005) as necessary.
Starter Frame and Magnet

1. Check the starter motor armature ( 11 005) for
damage and replace as necessary.

ALL RIGHTS RESERVED
SPECIFICATIONS

Description N·m lb-In Description N·m lb-In
Solenoid Bolt 5-10 45-89 Through-Bolt 5-10 45-89
M-Terminal Nut 9-14 80-124 Mounting Bolt 20-27 15-20
(Lb-Ft)
B-Terminal Nut 9-14 80-124
Brush Plate Screw 2-3 18-27
(Continued)
Starter Motor load Starter Brushes

Current Draw Normal Engine Mln.Stall
Motor Under Normal Cranking Torque@5 Spring
Diameter load Speed Volts Max. load No load Mfg. length Tension
101.6mm 130-220 Amps 140-220 rpm 14.7 N·m 800 Amps 70± 10 16.8mm 18N (64 oz.)
(4 Inches) (11.0 Lb-Ft> (0.66 Inch)
Maximum commutator runout is o. 12mm (0.005 inch). Maximum starting circuit voltage drop (battery positive terminal to
starter terminal) at normal engine temperature is 0.5 volt.
SPECIAL SERVICE TOOLS DESIRED ROTUNDA EQUIPMENT

Tool Number Description Model Description
D87L-420 1-A Dial Indicator 078-00005 Starting and Charging Tester
D87L-4201-B Magnetic Base 014-00407 Digital Volt-Ohmmeter
ALL RIGHTS RESERVED
03-068-1 Starting System, Diesel Engines 03-068-1
SECTION 03·068 Starting System, Diesel Engines

VEHICLE APPLICATION .....••............•.......................03-o6B-1 DESCRIPTION AND OPERATION ................•.............03-06B-1
VEHICLE APPLICATION


ALL RIGHTS RESERVED
03-07A-1 Ignition, Distributor 03-07A-1
SECTION 03·07A Ignition, Distributor

VEHICLE APPLICATION ............•...•..••••••.....•............03-o7A-1 DISASSEMBLY AND ASSEMBLY
DESCRIPTION AND OPERATION Distributor•.•.....••.•••.............................••..•.....••••••03-07A-a
Ignition Coil .....••••••....•.................•.....•.........•••.....03-o7A-1 CLEANING AND INSPECTION
Ignition Control Module ..•••••......•••.......................03-o7A-1 Distributor...•........•••••.......•••••...•..•..•........•••••.•.•.••03-07A-a
Ignition System Features ••..•....•......................•....03-07A-1 Distributor Cap ..........................••..•..•.••••••....•••••••03-07A·a
Universal Distributor..••..............•••••.•••.....•.........••03-07A-2 Distributor Rotor ...••••••......••••....•....•.......•..•.........03-07A·a
DIAGNOSIS AND TESTING....•.........•.........•............•.03-o7A-2 Ignition ColI(s) .....••.••........•.......•..............••......••03-07A-10
REMOVAL AND INSTALLATION Ignition Wires ..•....................••••......••.........••......03-07A-1 0
Distributor.•............•.•.........••....•.••....................•..03-07A-3 Spark Plugs 03-07A-a
Distributor Cap ••.•••......•.........••.•................•••••..••.03-07A-2 ADJUSTMENTS
Distributor Rotor .........................••••••..................03-07A-3 Ignition Timing 03-07A-1 0
Ignition Coil .....•..•.•......••....................•..•......•••••...03-07A-6 Spark Plugs 03-o7A-10
Ignition Control Module ........•.•....••••.•.•.....••••.......03-07A-6 SPECIFICATIONS 03-07A-1 0
Ignition Wires .......•.........•...••..................••••........•03-07A-7 SPECIAL SERVICE TOOLS/EQUIPMENT •••..••..••••...03-o7A-11
Spark Plugs ...................•.•.................•..........••••...03-o7A-7
Stator................................•............•.•..........•.......03-07A-4
VEHICLE APPLICATION
F-Series and aronco
Ignition System Features Initial timing adjustments are only required when the
NOTE: This section is to serve as a guide in distributor has been moved from its factory setting or
removed from the engine (6007). Ignition timing
understanding, testing and servicing the Distributor
Ignition (01) system. Many of the parts are matched, procedures and diagnostics are found in the
1
Powertrain Control/Emissions Diagnosis Manual.
for example, the S.al lightning distributor has a
specific gear matched to its specific camshaft. When There are two 01 type systems: Push-Start and
replacing any component, use only the proper service Computer-Controlled Dwell. The push-start mode will
replacement part. allow manual transmission vehicles to be push-started.
(Do not attempt to push-start automatic transmission
NOTE: Do not change the octane rods without proper
vehicles.) The Computer-Controlled Dwell ignition
authorization; state or federal emission requirements
features PCM controlled ignition coil charge times.
will be affected.
The 01 system features a camshaft-driven distributor
(12127) without centrifugal or vacuum advance. The
distributor has a diecast base with a Hall effect stator
assembly.
Ignition Coil • On the ignition coil primary circuit into as much as

The ignition coil (12029) transforms battery voltage: 40K volts on the secondary circuit, each time the
ignition coil receives a signal from the ignition
control module (ICM)(12A297).
Ignition Control Module

The ignition control module (ICM)( 12A297) with
computer-controlled dwell (CCD), features powertrain
control module controlled ignition coil charge times.

ALL RIGHTS RESERVED
Universal Distributor During this time, a voltage is produced as the vane

The universal distributor (12127) has a Hall effect passes through the opening. When the vane clears the
vane switch assembly to allow the ignition coil (12029) opening, the window edge causes the signal to go to
to be switched off and on by the powertrain control zero volts. This signal is used by the powertrain
module (PCMX 12A650) and ignition control module control module for crankshaft position sensing and the
(ICMX12A297). The vane switch is an encapsulated computation of the desired spark advance based on
package consisting of a Hall effect device on one side engine demand and calibration. The conditioned spark
and a permanent magnet on the other side. advance and voltage distribution is done with a
conventional distributor rotor (12200), distributor cap
(12106) and spark plug wire set (12259).
PERMANENT HALL
MAGNET EFFECT
DEVICE
B4144-A
84147·A
The distributor armature (12A099) is made of ferrous
metal and is used to trigger the signal off and on.
Refer to the Powertrain Control/Emissions Diagnosis

2
Manual for diagnosis and testing procedures of the
distributor ignition system.
WINDOW REMOVAL AND INSTALLATION

84145-A
Distributor Cap
When the window of the distributor armature is
between the magnet and the Hall effect device a Removal
magnetic flux field is completed from the magn~t 1. Loosen distributor cap hold-down screws.
through the Hall effect device and back to the magnet.
2. Lift distributor cap (12106) with attached wire
set straight off of distributor (12127) to prevent
damage to the rotor blade and spring.
CRACK OR
CARBON
TRACK
SQUARE
ALIGNMENT
LOCATOR
PERMANENT
MAGNET
84146-A
As the vane passes through this opening, the flux lines CARBON
are shunted through the vane and back to the magnet. BUTION
B4428-A

ALL RIGHTS RESERVED
Installation 2. Mark position of No. 1 cylinder wire tower on

1. Inspect distributor cap for cracks, broken carbon distributor base adapter ( 12A217) for reference
button, carbon tracks, and terminals for dirt or when reinstalling the distributor (12127).
corrosion. 3. Loosen distributor cap hold-down screws.
2. Replace the distributor cap if damage is found. 4. Lift distributor cap (12106) with attached wire
3. Reinstall any ignition wire and bracket (12280) set straight off of distributor to prevent damage
removed in their proper locations. to the rotor blade and spring.
4. Install the distributor cap noting the square 5. Position distributor cap and attached wire set
alignment locator, with attached wire set straight aside so as not to interfere with removal.
on the distributor. This will prevent damage to the 6. Check if distributor rotor blade is pointing toward
rotor blade and spring. the marked position on the distributor base
5. lighten distributor cap hold-down screws to adapter that was previously made. If the
2.0-2.6 N·m (18-23Ib-in). distributor rotor blade is one half a revolution off,
rotate the crankshaft one full revolution and
realign timing pointer with TDC on crankshaft
vibration damper.
Distributor Rotor 7. Disconnect distributor to wiring harness.
8. Remove distributor rotor (12200) by pulling
Removal and Installation upward on the distributor rotor from the
1. Remove distributor cap (12106) as outlined. distributor shaft.
2. Remove distributor rotor (12200) by pulling 9. Remove distributor hold-down bolt and clamp.
upward on the distributor rotor from the
10. Remove distributor from cylinder block by pulling
distributor shaft.
upward with a slight side to side twist.
3. Inspect distributor rotor for cracks, carbon
11. Cover distributor opening in cylinder block with a
tracks, burns, or damage.
clean shop towel to prevent the entry of foreign
4. Replace the distributor rotor if damage is found. material into the engine.
5. Align the locating boss and fully seat the Installation
distributor rotor on the distributor shaft.
1. NOTE: When installing the distributor, No.1
6. Reinstall distributor cap as outlined. piston must be at TOC of the compression stroke.
Visually inspect the distributor. The a-ring should
fit tight onto the housing free of cuts. The drive
gear should be free of nicks, cracks, or
excessive wear. The distributor shaft should
rotate freely, without any binding.
2. Lubricate the distributor gear teeth with a coating
of fresh motor oil or with Engine Assembly
Lubricant D9AZ-19579-D meeting Ford
specification ESR-M99C80-A.
3. Align the locating boss and fully seat the
.distributor rotor on the distributor shaft.
4. Rotate the distributor shaft so that the distributor
rotor blade is pointing toward the marked position
on the distributor base adapter.
5. Install the distributor into the cylinder block with a
slight side to side twist.
6. NOTE: If the vane and vane switch assembly can
LOCATING BOSS not be kept on the leading edge after installation,
(PART OF 12200) remove the distributor from cylinder block by
pulling upward enough for the distributor gear to
85726-8 disengage from the camshaft gear. Rotate
distributor rotor enough so that the gear will align
on the next tooth of the camshaft gear.
Rotate the distributor in the engine to align the
Distributor leading edge of the vane to the vane switch
assembly. Verify that the distributor rotor blade is
Removal pointing toward the marked position on the
1. Align timing pointer with Top Dead Center (TDC) distributor base adapter.
on crankshaft vibration damper.
1995 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain July 1994.

ALL RIGHTS RESERVED
7. Install finger-tight the distributor hold-down bolt 3. Remove armature.

and clamp. 4. Mark the collar (5.0l, 5.8l, 7.5L) and distributor
8. Install the distributor cap with attached wire set gear with a felt tip pen for reference when
straight on the distributor to prevent damage to reinstalling the distributor gear.
the rotor blade and spring. 5. Remove and discard the roll pin from both the
9. lighten distributor cap hold-down screws to gear and collar (5.0l, 5.8l, 7.5L).
2.0-2.6 N·m (18-23Ib-in). 6. Invert the distributor and place in the Axle
10. Connect distributor to wiring harness. Bearing/Seal Plate T75l-1165-B. Press off the
11. Set initial timing according to procedures in the gear Bearing Pulling Attachment D79L-4621-A or
Powertrain Control/Emissions Diagnosis equivalent.
Manual. 3
12. lighten distributor hold-down bolt and clamp to
23-34 N·m (17-25 Ib-ft) without moving timing
~I I~
adjustment.
Stator
I Description I Tool Number I
I Axle Bearing I Seal Plete I T75L-1165-B I
CAUTION: Do not attempt to replace stator
without an arbor press. 7. Remove the thrust washer from the distributor
CAUTION: The drive gear on distributors (12127) (4.9l engine only).
is not released for service. If any nicks or cracks 8. Deburr and polish the shaft with emery cloth so
occur during the disassembly or reassembly the shaft assembly will slide out freely from the
procedures, a new distributor must be used. The distributor base.
distributor drive gear Is matched to the
distributor at assembly and should never be 9. Remove the shaft assembly.
replaced. Although some of the drive gears for 10. Remove the distributor stator assembly screw
other distributors may physically fit the and retainer.
distributor, they must not be used. Whenever
damage or excessive wear is noted on the drive 11. Remove the octane rod screw, octane rod, and
gear, it must be replaced with a new distributor. retainer.
12. Remove the distributor stator (12A 112) from the
Removal top of the bowl.
1. Remove distributor assembly as outlined.
2. NOTE: Hold drive gear to loosen the armature
screws; do not hold the distributor armature.
Remove two armature retaining screws.

ALL RIGHTS RESERVED
Closed Bowl Distributor 5.0L, 5.8L, 7.5L (4.9L Similar)
DISASSEMBLED ASSEMBLED
VIEW VIEW B511M1
Part Part
1 - Screws (2 Req'd) 6 - Base Assembly
(Part of 12127) (Part of 12127)
2 - Shaft Assembly 7 - Collar (Part of 12127)
(Part of 12127) 8 - Hall Effect Vane Stator
3 - Rotary Vane (Part of 12127) Switch Assembly
4 - Octane Rod (Part of 12127) (Part of 12127)
5 - Connector (Part of 12127) 9 - O-Ring (Part of 12127)
(Continued)
Installation 7. Lubricate lightly the shaft assembly with a

1. Inspect distributor base housing and bushings for coating of fresh motor oil or with Engine
any indication of excessive heat concentration, Assembly Lubricant D9AZ-19579-D meeting
cracks, or wear. Replace complete distributor if Ford specification ESR-M99CSQ-A.
damage is found. S. Install the shaft assembly into the distributor base
2. Position distributor stator on the bushing of the housing.
distributor base housing and press into place. 9. Place a 1/2 inch deep well socket over the end of
3. Position distributor stator connector tab into the the shaft assembly.
notch of the distributor base housing so that the 10. Invert the distributor and place on the arbor
eyelets will align with the screw holes. press.
4. Position distributor stator connector wires away 11. Install the gear thrust washer on the distributor
from any moving parts. (4.9L engine only).
5. Install the distributor stator assembly screw and 12. Install the collar and collar pin (5.0L, 5.SL, 7.5L).
retainer. Tighten screw to 1.7-4.0 N·m (15-35
Ib-in).
6. Install the octane rod, octane rod screw, and
retainer. Tighten screw to 1.7-4.0 N·m (15-35
Ib-in).

ALL RIGHTS RESERVED
13. NOTE: The hole in the drive gear and shaft 15. Insert new pin through the distributor gear. The
assembly must be aligned as accurately as pin should be flush (4.9l, 5.0l, 5.8l). The pin
possible to allow for ease of the roll pin insertion. extrusion should be equal on either side of the
CAUTION: The drive gear on distributors is gear (7.5l).
not released for service. If any nicks or 16. Install distributor armature.
cracks occur during the disassembly or 17. NOTE: Hold drive gear to tighten the armature
reassembly procedures, a new distributor screws; do not hold the distributor armature.
must be used. The distributor drive gear is
matched to the distributor at assembly and Install the armature retaining screws and tighten
should never be replaced. screws to 2.8-4.0 N·m (25-35Ib-in).
NOTE: If the hole in the drive gear and shaft 18. NOTE: If the distributor armature contacts the
assembly will not align, the gear must be removed distributor stator, the entire distributor must be
and attempted again. The gear can not be turned replaced.
for alignment. The distributor shaft should rotate freely, without
Install the distributor gear on the shaft assembly any binding.
and align the distributor gear with the felt tip 19. Install the distributor assembly and reset initial
reference. timing as outlined.
14. Place a 5/ 8-inch deep well socket centered
around gear hole and press the distributor gear
onto the shaft assembly.
Ignition Coil
1. Disconnect engine control sensor wiring at
ignition coil connector.
2. Disconnect ignition coil ignition wire at ignition coil
(12029).
3. Remove ignition coil to bracket retainer screws
and remove ignition coil.
4. Reverse removal procedure (to install ignition
coil). Tighten ignition coil to bracket retainer
screws to 2.8-4.0 N·m (25-35 Ib-in).
Ignition Control Module

Removal
1. Remove two screws retaining ignition control
module (ICM)( 12A297) heatsink assembly to left
fender apron.
2. Disconnect harness connector from ignition
control module.
3. Remove two screws retaining ignition control
module (ICM)( 12A199) to heatsink and remove
ignition control module.
B4142-A ~I
B5729·A

ALL RIGHTS RESERVED
03·07A·7 Ignition, Distributor 03·07A-7
Installation
SPARK PLUG WIRE REMOVER
1. Coat metal baseplate of the ignition control T74P-6666-A
module uniformly with silicone compound,
approximately .0 179mm (1 /'32-inch) thick. Use
Silicone Dielectric Compound WA-10
D7AZ-19A331-A (ESE-M 1C 171-A) or equivalent.
2. Position ignition control module onto heatsink and
tighten two retaining screws to 12-18 N·m (11-16
Ib-in).
3. Install ignition control module heatsink assembly
to left fender apron using two retaining screws, TWIST AND PULL
and tighten to 9-14 N·m (8Q-1241b-in).
4. Connect engine control sensor wiring (12A581) A24035-A
to the ignition control module.
2. When removing ignition coil to distributor high
F-150, F-250, F-350, F-Super Duly and Bronco tension wiring (12298) or distributor to spark plug
wire from distributor cap (12106) or ignition coil
(12029), grasp boot by hand and remove with
leM AND twisting motion. Do not pull on wire.
HEATSINK
ASSEMBLY Installation
128582
~ 1. Whenever an ignition coil to distributor high
FRONT OF
VEHICLE tension wiring is removed for any reason from a
spark plug, or distributor cap, or a new ignition
coil to distributor high tension wiring is installed,
Silicone Dielectric Compound D7AZ-19A331-A
meeting Ford specification ESE-M 1C 171-A or
equivalent must be applied to boot before it is
reconnected. Using a small clean tool, coat entire
interior surface of boot with Silicone Dielectric
Compound D7AZ-19A331-A meeting Ford
specification ESE-M 1C 171-A or equivalent.
2. Insert each distributor to spark plug wire and
ignition coil to distributor high tension wiring on
proper terminal of distributor cap. Make sure
distributor high tension wiring are all the way
down over their terminals. The No. 1 terminal is
identified on distributor cap. Install distributor to
spark plug wires and ignition coil to distributor
high tension wiring starting with No. 1 terminal.
3. Remove ignition wire separator (12297) from old
spark plug wire set (12259) and install them on
85727-A
new set in same relative position. Install
distributor high tension wiring in ignition wire
separators on valve cover (6582).
Ignition Wires 4. Connect distributor to spark plug wire to proper
spark plugs.
5. Install ignition coil to distributor high tension wiring
Description Tool Number to the distributor cap.
Spark Plug Wire Remover Tool T74P-6666-A
Removal
1. When removing distributor to spark plug wire
Spark Plugs
( 12286) from spark plugs (12405), use Spark Removal and Installation
Plug Wire Remover Tool T74P-6666-A. Grasp
1,. Remove air cleaner inlet tube assembly as
and twist the boot back and forth on plug insulator
required.
to free boot. Use special tool to pull boot from
plug. Do not pull on distributor to spark plug wire 2. Using Spark Plug Wire Remover Tool
directly, or it may become separated from T74P-6666-A, grasp and twist boot off spark
connector inside boot. plug (12405).

ALL RIGHTS RESERVED
REMOVAL AND INSTALLATION (Continued) CLEANING AND INSPECTION
3. Using appropriate socket, extension and socket Distributor Cap

wrench, loosen spark plugs and remove any dirt Wash both inside and outside surfaces of the
or foreign material from spark plug areas of distributor cap (12106) with soap and water. Dry
cylinder head with compressed air. Remove distributor cap with compressed air. Inspect distributor
spark plugs from cylinder block (6010). cap for cracks, broken carbon button or carbon
4. Refer to the Spark Plug Inspection Chart to tracks. Also, inspect distributor cap terminals for dirt
determine spark plug condition. Replace spark and corrosion. Replace the distributor cap if it is
plugs as required. damaged.
5. Using an appropriate gapping tool, check and set
the spark plug electrode gap to specifications.
Refer to the Vehicle Emission Control Information
(VEel) decal located in the engine compartment. Distributor
6. Install spark plugs into cylinder block. lighten to Inspect distributor Q-ring.lt should fit tightly and be
9-20 N·m (7-151b-ft). For 4.9L tighten to 20-27 free of cuts. Drive gear should be free of nicks, cracks
N·m (15-20 Ib-ft). and excessive wear. Rotate distributor driveshaft. It
7. Coat entire interior surface of ignition wire boot should move freely without binding.
with Silicone Dielectric Compound
D7AZ-19A331-A, WA-10 meeting Ford
specification ESE-M1C171-A or equivalent.
Install onto proper spark plug. Make sure spark Distributor Rotor
plug wire set (12259) is completely seated. Wash distributor rotor (12200) with soap and water.
8. Install air cleaner inlet tube and inside engine Dry with compressed air. Inspect and replace
cover, if required. distributor rotor if cracks, carbon tracks, burns or
damage to blade or spring are observed.
9. Start engine (6007) and check for proper
operation.

Spark Plugs
Clean spark plugs (12405) as necessary using a wire
brush or professional spark plug cleaner (follow
Distributor manufacturer's instructions). Inspect the firing tip.
Refer to stator removal and installation procedures for Refer to Spark Plug Inspection Chart. Replace if worn
disassembly and assembly of the distributor (12127). or damaged.

ALL RIGHTS RESERVED
Spark Plug Inspection Chart
GAP BRIDGED OIL FOULED
IDENTIFIED BY WET BLACK

IDENTIFIED BY DEPOSIT BUILD- DEPOSITS ON THE INSULATOR
UP CLOSING GAP BETWEEN SHELL BORE ELECTRODES.
ELECTRODES.
CAUSED BY OIL OR CARBON CAUSED BY EXCESSIVE OIL
FOULING, REPLACE PLUG. OR, ENTERING COMBUSTION CHAMBER
IF DEPOSITS ARE NOT EXCESSIVE THROUGH \NORN RINGS AND
THE PLUG CAN BE CLEANED. PISTONS, EXCESSIVE ClEARANCE
BETWEEN VALVE GUIDES AND
STEMS, OR \NORN OR LOOSE
BEARINGS. CORRECT OIL
PROBLEM. REPLACE THE PLUG.
CARBON FOULED NORMAL PAE-IGNITION
IDENTIFIED BY BLACK, DRY FLUFFY IDENTIFIED BY MELTED ELECTRODES

CARBON DEPOSITS ON INSULATOR AND POSSIBLY BLISTERED INSULATOR.
TIPS, EXPOSED SHELL SURFACES AND IDENTIFIED BY LIGHT TAN OR GRAY METALlO DEPOSITS ON INSULATOR
ELECTRODES. DEPOSITS ON THE FIRING TI~ INDICATE ENGINE DAMAGE.
CAUSED BY TOO COLD A PlUG, WEAK CAUSED BY WRONG TYPE OF FUEL,

IGNITION, DIRTY AIR CLEANER. INCORRECT IGNITION TIMING OR
DEFECTIVE FUEL PUMP, TOO RICH A ADVANCE, TOO HOT A PLUG, BURNT
FUEL MIXTURE, IMPROPERLY OPERATING VALVES OR ENGINE OVERHEATING.
HEAT RISER OR EXCESSIVE IDLING. REPLACE THE PLUG.
CAN BE CLEANED.
OVERHEATING FUSED SPOT DEPOSIT
IDENTIFIED BY A WHITE OR LIGHT

GRAY INSULATOR WITH SMAlL
BlACK OR GRAY BROWN SPOTS IDENTIFIED BY MELTED OR SPOTTY
AND WITH BLUISH-BURNT DEPOSITS RESEMBLING BUBBLES OR
APPEARANCE OF ELECTRODES. BUSTERS.
CAUSED BY ENGINE OVER· CAUSED BY SUDDEN ACCELERATION.

HEATING, WRONG TYPE OF CAN BE CLEANED IF NOT EXCESSIVE,
FUEL, LOOSE SPARK PLUGS, TOO OTHERWISE REPLACE PLUG.
HOT A PLUG, LOW FUEL PUMP
PRESSURE OR INCORRECT
IGNITION -TIMING. REPLACE
THE PLUG.

ALL RIGHTS RESERVED
Ignition Coil(s)
Wipe coil tower with a clean cloth dampened with
soap and water. Remove any soap film and dry with
compressed air. Inspect for cracks, carbon tracking
and dirt.
Ignition Wires
Without removing the ignition coil to distributor high
tension wiring (12298) from the spark plugs (12405),
distributor cap (12106) or ignition coil (12029), wipe
the ignition coil to distributor high tension wiring or
distributor to spark plug wire (12286) with a clean,
damp cloth and inspect them for visible damage such
as cuts, pinches, cracks or torn boots. Replace only
ignition coil to distributor high tension wiring or
distributor to spark plug wires that are damaged.
Refer to Ignition Wires Removal and Installation.
ADJUSTMENTS
Spark Plugs
Using a suitable spark plug gap tool, adjust spark plug
gap to the following:
IGNITION SYSTEM SPECIFICATIONS
Engine Spark Plug Type Spark Plug Gap Firing Order TIming
4.9L BSF-44C 1.07-1. 17mm (0.042-0.046 Inch) 153624 BTDC 10° ± 2°
5.0L ASF-42C 1.3-1.4mm (0.052-0.056 Inch) 13726548 BTDC 10° ± 2°
5.8L ASF-32C 1.07-1. 17mm (0.042-0.046 Inch) 13726548 BTDC 10° ± 2°
7.5L ASF-42C 1.07-1. 17mm (0.042-0.046 Inch) 15426378 BTDC 10° ± 2°
Ignition Timing TORQUE SPECIFICATIONS (Cont'd)

Refer to the Powertrain Control/Emissions Diagnosis Description N·m Lb·Ft Lb·ln
4
Manual for ignition timing procedures of the distributor ICM-to-Heatsink Screws 1.7-4.0 - 15-35
ignition (01) system. Base ignition timing is preset at
10° ± 2° BTDC. ICM / Heatsink 9-14 - 80-124
Assembly-to-Left Fender
Apron Screws
SPECIFICATIONS Distributor Cap Hold-Down 2.0-2.6 - 18-23

Screws
Octane Rod Retaining Screw 1.7-4.0 - 15-35
Distributor 2.8-4.0 - 25-35
Description N·m Lb-Ft Lb-In Adapter-to-Distributor Base
Distributor Hold-Down Bolts 23-34 17-25 - Armature Retaining Screws 2.8-4.0 - 25-35
Stator Assembly Screws 1.7-4.0 - 15-35 Coil-to-Bracket Retainer 2.8-4.0 - 25-35
Screws
Spark Plugs, 4.9L 20-27 15-20 -
Taperset Hex Body 68 50 -
Spark Plugs (Except 4.9L) 9-20 7-15 -
(Continued)


ALL RIGHTS RESERVED
SPECIAL SERVICE TOOLS REQUIRED SPECIAL SERVICE TOOLS DESIRED

Tool Number / Tool Number Description
D79L-4621-A Bearing Pulling Attachment
T75L-1165-B
~T7lIL-11'"
Axle Bearing / Seal Plate
T74P-6666-A
~
Spark Plug Wire Remover Tool
T74P-8888-A

ALL RIGHTS RESERVED
03-078-1 Glow Plug System 03-078-1
SECTION 03·078 Glow Plug System

VEHICLE APPLICATION ..•••...•.•••••••...•.••••...••..•.•..•....03-07B-1 DESCRIPTION AND OPERATION ....•..••••••...•.•.•••..•••..03-07B-1
VEHICLE APPLICATION
Vehicles Equipped with 7.3L DI Diesel Engines


ALL RIGHTS RESERVED
03-08-1 Engine Emission Control 03-08-1
SECTION 03·08 Engine Emission Control

VEHICLE APPLICATION .•...........................................03-08-1 IN-VEHICLE SERVICE (Cont'd.)
DESCRIPTION AND OPERATION PCV Hoses 03-08-3
Exhaust Emission Control System .....•....................03-08-2 Crankcase Vent Connector and Hose 03-08-3
Vehicle Emission Control Information Oil Separator Hose 03-08-3
Decal 03-08-2 PCV Valve 03-08-3
Exhaust Gas Recirculation (EGR) System 03-08-2 Secondary Air Solenoid, S.OL Typical 03-08-9
Positive Crankcase Ventilation (PCV) REMOVAL AND INSTALLATION
System 03-08-1 Secondary Air Injection Bypass (AIRB)
Secondary Air Injection Bypass (AIRB) Valve 03-08-10
Valve ...........................................•......................03-08-2 Secondary Air Injection Control Valve, S.8L
Secondary Air Injection Control Valve 03-08-3 Typical 03-08-10
DIAGNOSIS AND TESTING CLEANING AND INSPECTION
Engine Emission Control ................................•......•03-08-3 EGR Control Solenoid ~ 03-08-11
IN-VEHICLE SERVICE EGR Valve ........................................•...................03-08-11
EGR Control Solenoid ~ 03-08-9 PCV Valve 03-08-11
EGR Position Valve Sensor 03-08-8 Secondary Air Solenoid 03-08-11
EGR Valve 03-08-6 SPECIFICATIONS 03-08-11
EGR Valve to Exhaust Manifold Tube .•.•..................03-08-6 SPECIAL SERVICE TOOLS/EQUIPMENT 03-08-12
VEHICLE APPLICATION
F-150, F-250, F-350 and Bronco
Positive Crankcase Ventilation (PCV) System CAUTION: Do not remove the PCV system from
The positive crankcase ventilation (PCV) system the engine. Operating engine without PCV
cycles crankcase gases back through the engine system will reduce both fuel economy and engine
(6007) where they are burned. The positive ventilation. This will weaken engine performance
crankcase ventilation valve (PCV valve)(6A666) and shorten life.
regulates the amount of ventilation air and blow-by fuel
vapor to the intake manifold (9424) and prevents Typical PCV Air Flow Diagram
backfire from traveling into the crankcase. The
positive crankcase ventilation valve is mounted in a
vertical position.
A18842-B
Part
1 6582 Valve Cover
2 - To Air Cleaner Outlet Tube
(98659)
3 6758 Crankcase Ventilation Tube
4 9E926 Throttle 80dy
(Continued)

ALL RIGHTS RESERVED
Part
6 6A666 Positive Crankcase
Ventilation Valve
Exhaust Gas Recirculation (EGR) System The amount of exhaust gas reintroduced and the
The exhaust gas recirculation (EGR) system is timing of the cycle varies by calibration. liming and
designed to reintroduce exhaust gas into the volume are controlled by engine rpm, engine vacuum,
combustion cycle, lowering combustion temperatures exhaust system back pressure, engine coolant
and reducing the formation of Oxides of Nitrogen. temperature and throttle position. The EGR valve
(EGR valve)(9D475) is vacuum actuated. The vacuum
hose routing diagram is shown on the Vehicle Emission
Control Information (VECI) decal.
Exhaust Emission Control System

Vehicle Emission Control Information Decal
Vacuum hoses on the engine (6007) use a color stripe
to aid in hose routing checks. The stripe will usually be
the same color as on the VECI decal, but the correct
vacuum hose routing must be verified by using the
correct component connections shown on the VECI
decal.
Vehicle Emission Control Information Decal
FORD MOTOR COM NY VACUUM HOSE ROUTING

+
IMPORTANT VEHICLE FORMATION
THIS VEHICLE IS QUIPPED WITH EEC IV MFI STEMS. IDLE SPEEDS AND
IDLE MIXTURES ARE NOT ADJUSTABLE. SEE HOP MANUAL FOR ADDITIONAL
INFORMATION.
ADJUST IGNITION TIMING WITH THE TRANSMISSION IN NEUTRAL. I
PARKING BRAKE SET AND THE WHEELS BLOCKED. ENGINE MUST BE
AT NORMAL OPERATING TEMPERATURE. ~
I
(I) TURN OFF ENGINE. I
(2) DISCONNECT THE IN-LINE SPOUT CONNECTOR ( -O£; OR ~II ). I
(3) RE-START PREVIOUSLY WARMED-UP ENGINE. I
I
(5) TURN OFF ENGINE AND RESTORE ELECTRICAL CONNECTION. 11:0------
FIRING ORDER - 15426318 II ~~~~.II!!!!~I~
THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS APPLICABLE TO 1995 III
I I
MODEL YEAR NEW LIGHT-DUTY TRUCKS. COMPLIANCE P~MONSTRATED ANp
pESIGNEp FOR PRINCIPAL USE BELOW 4000 FEET FOR N W VEHICLE ~I
COMPl~A~CE ABOVE 4000 FEET. SEE SERVICE PUBLICATIONS.
~
TYPICAL VEHICLE EMISSION

CONTROL INFORMATlON DECAL
(UNDER 8500 GVW) A10418-F
Secondary Air Injection Bypass (AIRB) Valve

The secondary air injection bypass valve (98289) is
used:

ALL RIGHTS RESERVED
• In electronic controlled secondary air injection 2. Remove positive crankcase ventilation valve from
system. crankcase ventilation grommet (6A892).
• To divert secondary air to the atmosphere during 3. Inspect crankcase ventilation grommet for
some operating modes. deterioration and replace if necessary.
Secondary Air Injection Control Valve

The secondary air injection control valve (9F491) is PCVHoses
used:
Crankcase Vent Connector and Hose
• In electronic controlled secondary air injection Removal and Installation
systems.
1. Disconnect crankcase vent connector and hose
• To divert secondary air upstream to the exhaust (6C324) from valve cover (6582) and engine air
manifold check valve. cleaner (ACL)(9600).
• To divert secondary air downstream to the catalytic 2. Remove crankcase vent connector and hose.
converter check valve.
Oil Separator Hose
1. Disconnect emission vacuum control hose from
Engine Emission Control center of oil separator hose (6A664).
Refer to the Powertrain Control/Emissions
Diagnostics Manual. 1 2. Disconnect oil separator hose from positive
crankcase ventilation valve (PCV valve)(6A666)
and upper intake manifold (9424) and remove oil
separator hose.
IN-VEHICLE SERVICE
3. To install, reverse removal procedures.
PCVValve
1. NOTE: Removal of the positive crankcase
ventilation valve (PCV valve)(6A666) may require
removal of the upper intake manifold. Refer to
appropriate section in Group 03.
Disconnect oil separator hose (6A664) from
positive crankcase ventilation valve.


ALL RIGHTS RESERVED
Non-A/C and Non-Super Cooling, Typical5.0L Shown
~
FRONT OF VEHICLE
A10207-D
Part Part
1 9600 Engine Air Cleaner 4 6A666 Positive Crankcase
2 6C324 Crankcase Vent Connector Ventilation Valve
and Hose 5 6A664 Oil Separator Hose
(Continued)

ALL RIGHTS RESERVED
..
PCV Valve and Hoses, S.8l Engine
FRONT OF ENGINE
1
A15804-B
Part Part
1 9424 Intake Manifold, Upper 7 6762 Elbow
2 9A474 Intake Manifold Vacuum 8 6A892 Crankcase Ventilation
Outlet Fitting and Cap Grommet
3 381188 Hose A - Apply Sealer D8AZ-19554-A
4 6A666 Positive Crankcase (ESE-M4G 194-8) to
Ventilation Valve Threads. Tighten to 8-11 N·m
(6-8 Lb-Ft). Advance to
5 8287 Clamp Position Shown. Do Not Back
6 6A664 Oil Separator Hose Up.
(Continued)

ALL RIGHTS RESERVED
5.8L Lightning Engine 5.8L Lightning Engine
THROTTLE
BODY
ASSEMBLY
NIPPLE
A17866-B
Part
1 6853 Crankcase Ventilation Hose
2 6767 Crankcase Ventilation Hose
..
Connector, Elbow
3 6A666 Positive Crankcase
Ventilation Valve FRONT OF
VALVE COVER
4 6A892 Crankcase Ventilation ENGINE ASSEMBLY
Grommet NIPPLE
A17839-B
5 6A631 Crankcase Vent Oil
Separator Element
EGRValve
1. Remove the air cleaner outlet tube (98659).
2. Disconnect the EGR valve sensor wire harness at
EGR valve sensor (9G428).
tube (90477) from EGR valve (EGR
valve)(9D475) and vacuum hose.
4. Remove EGR valve retainer bolts and EGR valve
from upper intake manifold (9424).
5. Remove EGR valve gasket (90476). Clean
residue from upper intake manifold gasket
surface.
6. To install, reverse removal procedure. Tighten
EGR valve to exhaust manifold tube nut 34-47
N·m (25-35 Ib-ft).
EGR Valve to Exhaust Manifold Tube

1. Remove the air cleaner outlet tube (98659).

ALL RIGHTS RESERVED
2. Disconnect the EGR valve sensor wire harness at

EGR valve sensor (9G428). Part
3. Disconnect EGR valve to exhaust manifold tube
(90477) at EGR valve (EGR valve)(9D475) and 3 - EGR Tube Nuts (2)
(Part of 90477)
exhaust manifold.
4 N803575 Adapter
4. Remove EGR valve tube-to-manifold connector 5 9J444 Intake Manifold Support
from exhaust manifold, if required.
6 388377 Stud Hex Shoulder,
5. To install, reverse removal procedure. Tighten 5/16-18-18 x 1.85
EGR valve to exhaust manifold tube to EGR valve 7 45358 Nut, 3/8-16
and exhaust manifold to 34-47 N·m (25-35Ib-ft). 8 9430 Manifold, Exhaust
EGR System, S.Ol Engine (25-35 Lb-Ft)
•
FRONT OF ENGINE (15-20 Lb-Ft)
(12-18 Lb-Ft)
VIEW A
A16236-C
Part
1 90460 Exhaust Gas Recirculation
Valve
Manifold Tube
(Continued)
ALL RIGHTS RESERVED
EGR System, S.8l Engine
6 ,-----~--___ki;",.}
A15808-C
Part Part
1 9424 Intake Manifold, Upper 6 9J444 Intake Manifold Support
2 90477 EGR Tube Assembly 7 Stud, 5/16-18 x 1.85 (2)
3 - EGR Tube Assembly Nuts (2) 8 90475 EGRValve
(Part of 90477) 9 90476 EGR Valve Gasket
4 9F485 EGR Valve Tube to Manifold A - Tighten to 34-47 N·m
Connector (Must be installed (25-35 Lb-Ft)
with flanged shoulder toward B - Tighten to 54-68 N·m
exhaust manifold.) (40-50 Lb-Ft)
5 14A163 Wiring Retainer C - Tighten to 18-26 N·m
EGR Valve Position Sensor

EGR VALVE SENSOR
Removal and Installation (REMOVABLE)
9G428
1. Disconnect EGR valve sensor wire connector at
EGR valve sensor (9G428).
2. Remove three EGR valve sensor retaining nuts.
3. Remove EGR valve sensor from EGR valve (EGR EGRVALVE
9F483
valve)(9D475). Inspect and replace silicon gasket
(if necessary).
EGR valve sensor retaining nuts to 16 N~
(12 Ib-ft).
A20935-A

ALL RIGHTS RESERVED
EGR Control Solenoid 4. Remove nuts and slide the EGR vacuum regulator
control off the mounting bracket.
Removal
1. Disconnect the battery ground cable. Installation
2. Disconnect vacuum hoses. To install, reverse the removal procedure.
3. Disconnect the EGR vacuum regulator control
(9J459) electrical connector.
Secondary Air Solenoid, 5.0L Typical 4. Slide the secondary air injection control solenoid
vacuum valve off the mounting bracket.
Removal
1. Disconnect the battery ground cable. Installation
2. Disconnect vacuum hoses. To install, reverse the removal procedure.
3. Disconnect the secondary air injection control
solenoid vacuum valve (9H465) electrical
connector.
5.0L Engine, Typical
~~
,It
•
FRONT OF VEHICLE
4
A23678-A
Part Part
1 9H465 Secondary Air Injection 3 9J459 EGR Vacuum Regulator
Control Solenoid Vacuum Control
Valve 4 N620479-S50 Nut
2 9H472 Mounting Bracket 5 9E498 Vacuum Hose
(Continued)
ALL RIGHTS RESERVED
Secondary Air Injection Bypass (AIRB) Valve 3. Remove hoses from secondary air injection
bypass valve (98289).
Removal
4. Remove secondary air injection bypass valve
1. Remove nut and bracket holding secondary air from vehicle.
injection bypass valve inlet hose and tube
(9H300). Installation
2. Remove clamps from secondary air injection To install, reverse removal procedures.
bypass valve hoses.
Secondary Air Injection Control Valve, 5.8L 3. Remove secondary air injection control valve
Typical from vehicle.
1. Remove clamps from secondary air injection To install, reverse removal procedures.
control valve hoses.
2. Remove hoses from secondary air injection
control valve (9F491).
j
•
FRONT OF ENGINE
VIEW A
4
FRONT OF ENGINE
~
Part Part
1 9F491 Secondary Air Injection 5 383745-S2 Nut, 3/8x 16
Control Valve 6 - Bracket (Part of 9H300)
2 - Hose (Part of 9F491) 7 9B289 Secondary Air Injection
3 9H447 Clamp Bypass Valve
4 9H300 Secondary Air Injection
Bypass Valve Inlet Hose and
Tube
(Continued)
ALL RIGHTS RESERVED
03·08·11 Engine Emission Control 03·08·11
PCVValve 6. If not as specified, replace the EGR vacuum

Cleaning of the positive crankcase ventilation valve regulator control.
(PCV valve)(6A666) is not recommended. Refer to
Section 00-03 for the recommended positive
crankcase ventilation valve maintenance mileage
interval. The positive crankcase ventilation valve Secondary Air Solenoid
should be replaced at the specified mileage intervals. 1. Disconnect the vacuum hoses.
Shake positive crankcase ventilation valve and
carefully inspect for splits or cracks. If positive 2. Blow through the secondary air injection control
crankcase ventilation valve does not rattle or is solenoid vacuum valve (9H465) and verify that air
damaged, replace positive crankcase ventilation flows.
valve. 3. Disconnect the secondary air injection control
solenoid vacuum valve electrical connector.
4. Apply battery voltage and a ground to the
secondary air injection control solenoid vacuum
EGRValve valve as shown.
Inspect the EGR valve (EGR valve)(9D475) for
blockage or contamination. Clean EGR valve using SECONDARY AIR
Rotunda EGR Valve Cleaner 021-0056A or equivalent SOLENOID VALVE
following manufacturer's instructions. Inspect EGR
valve for vacuum leakage, replace if necessary.
EGR Control Solenoid

1. Disconnect the vacuum hoses.
2. Blow into the EGR valve (EGR valve)(9D475) and
verify that air does not flow.
3. Disconnect the EGR valve electrical connector.
A23681-A
4. Apply battery voltage and a ground to the EGR
vacuum regulator control (9J459) as shown. 5. Blow into the secondary air injection control
solenoid vacuum valve and verify that air does not
flow.
6. If not as specified, replace the secondary air
injection control solenoid vacuum valve.
SPECIFICATIONS
Description N'm Lb-Ft
EGR Valve to Upper Intake 20-30 15-22
Manifold
A23680-A EGR Valve to Exhaust Manifold 34-47 25-35
Tube Nuts
5. Blow through the EGR vacuum regulator control EGR Valve Sensor Retainer Nut 16 12
and verify that air flows.

ALL RIGHTS RESERVED
ROTUNDA EQUIPMENT
Model Description
021-80056 Rotunda EGR Valve Cleaner

ALL RIGHTS RESERVED
03-12-1 Air Intake 03-12-1
SECTION 03-12 Air Intake

VEHICLE APPLICATION .•.......•..•.•...•........•..•...•...•......03·12·1 REMOVAL AND INSTALLATION (Cont'd.)
DESCRIPTION AND OPERATION Engine Air Cleaner Intake Duct and Tube, 7.3L
Air Cleaner Element ................••.•..•..•.•.....••..•.........03·12·1 Direct Injection Diesel Englne ••••••••••••.••••••••.••••••• 03·12·~
Air Induction System •.••.•••...•.•.••..........•..•...•...••••••••03·12·1 Engine Air Cleaner, Gasoline Englnes..•••••••.•.......... 03·12·~
Air Restriction Gauge .......••.•.•••..•.•..•.............••.......03·12·2 CLEANING AND INSPECTION
DIAGNOSIS AND TESTING Air Cleaner Element •.•.••..•••..•..•.•....•.....••.•••...•......03·12·1 (l
Air Intake System ..•................•.•.•.•..••..•..•.......•......03·12·2 Air Inlet Restriction Check ..••...••.•.••••••••.••••••••••••••03·12·1 (l
REMOVAL AND INSTALLATION Engine Air Cleaner ••.•••...•...•••.•..•...••.•••.•.•••.•••.......03·12·1 (l
Air Cleaner Element, 7.3L Direct Injection SPECIFICATIONS .••.••...••..••..•.••.•..•..•••••••.•.•.•.•.•.••••••03·12·1 (l
Diesel Engine .•...••.•..•..•..•..•.•..•.••..•.••..•..••.•.••••••••03·12·3
Air Cleaner Outlet Tube, 7.3L Direct Injection
Diesel Engine .......................••.•..•...•..•...•..••....•...03·12·9
VEHICLE APPLICATION
F-Series and Bronco
Air Induction System

Air enters a dry-type engine air cleaner (ACL)(9600)
and travels through a pleated, chemically treated,
water resistant paper air cleaner element (ACL
element)(960 1) to remove contaminants before
entering the engine induction system. The 7.3L DI
turbo diesel engine also uses a pleated-paper panel
type element which features an expanded foam filter
media attached to the sides of the paper. Use of other
than specific Ford replacement filters may result in
significantly shortened filter life and consequent dirt
injection.
Air Cleaner Element On diesel engines, replace air cleaner element

Dry-type engine air cleaners (ACL)(9600) are according to air restriction gauge.
standard on all light truck vehicles.
Air enters the engine air cleaner and travels through a
chemically treated and pleated paper air cleaner
element (ACL element)(960 1) before entering the
engine induction system., The air cleaner element
should be inspected, cleaned, or replaced periodically
according to the schedule in Section 00-03. The air
cleaner system has an engine coolant temperature
sensor (ECT sensor)( 12A648) mounted in the engine
air cleaner to monitor inlet air temperature (on some
models).
ALL RIGHTS RESERVED
03·12·2 Air Intake 03·12·2
Air Restriction Gauge

The 7.3L diesel air induction system uses an air
restriction gauge to indicate when to replace the air
filter element. The air filter element should be replaced
when the yellow band in the restriction gauge reaches
the "CHANGE FILTER" mark. Engine performance
and fuel economy are adversely affected when
maximum restriction is reached. After servicing the air
filter element, the restriction gauge can be reset by
pushing the button on the end of the gauge. The
restriction gauge is located on the clean-air side of the
air cleaner upper housing.
AIR RESTRICTION GAUGE V5191-C
Air Intake System

1
Manual.
Engine Air Cleaner Intake Duct and Tube, 2. Disconnect duct from housing.
7.3L Direct Injection Diesel Engine For installation, follow removal procedures in reverse
order. lighten retaining screws to 7-9 N·m (62-80
Removal and Installation Ib-in).
1. Remove screw retaining air cleaner duct to
radiator support.
Engine Air Cleaner Intake Duct Assembly
2 4
3
5
9
JC~~ ---rBJ®
~~ '-/
~'.\\
Y5247-B

ALL RIGHTS RESERVED
03-12-3 Air Intake 03-12-3
Part Part
1 6K682 Turbocharger 7 - Nut (Part of 9600)
2 - Compressor Duct Elbow 8 N800576-S2 Screw
Clamp (Part of 6K682) 9 9A624 Engine Air Cleaner Intake
3 - Compressor Duct Elbow Tube
(Part of 6K682) 10 - Clamps (Part of 98676)
4 98676 Engine Air Cleaner Duct Tube A - Tighten to 7-9 N·m
Adapter (62-80 Lb-In)
5 9600 Engine Air Cleaner 8 - Tighten to 1.5-2.5 N·m
6 9N622 Restriction Gauge (13-22 Lb-In)
(Continued)
Air Cleaner Element, 7.3L Direct Injection 4. Replace engine air cleaner intake tube. Install
Diesel Engine screw to attach engine air cleaner intake tube to
radiator support. lighten to 7-9 N·m (62-80 Ib-in).
Removal
1. Remove engine air cleaner intake tube (9A624)
(see Engine Air Cleaner Intake Duct Removal and
Installation). Engine Air Cleaner, Gasoline Engines
2. Loosen hose clamp retaining engine air cleaner Refer to the illustrations in this section for removal and
(ACL)(9600) to engine air cleaner duct tube installation of the various types of engine air cleaners
adapter (9B676). (ACl)(9600). Reference to the illustrations will enable
3. Loosen nuts retaining upper air cleaner housing to the service technician to perform the required removal
lower air cleaner housing. Remove upper and installation or repair operations. For all engines,
housing. refer to the following procedure.
4. Before installing new element in air cleaner Removal
assembly, check the following items: 1. loosen two hose clamps securing hose
assembly to engine air cleaner (one clamp for
• gasket surfaces should be clean and
5.8l lightning).
undamaged.
2. Remove two screws attaching engine air cleaner
• air cleaner element (ACl element)(960 1)
. should be dry and free of holes, ruptures, to bracket.
damaged gaskets or dents in housings and 3. Disconnect hose and inlet tube from air closure
liners. hose/filter pack.
• water drain tube should be free of obstructions. 4. Remove screws attaching air cleaner cover.
Installation 5. Remove air filter and tubes.
CAUTION: A special filtering element is required Installation
on DI turbo engines. Use only a specific Ford 1. Set air cleaner element (ACl element)(960 1) into
replacement. Use of other elements could result proper position.
in serious engine damage. Do not attempt to
clean element. Discard and replace. 2. Position air cleaner cover to tray. Make sure air
cleaner element is seated while positioning cover.
After the air cleaner housing, air cleaner element and
other parts are found in good condition, reassemble 3. Install screws to secure cover.
the parts. 4. Install two bolts to secure engine air cleaner to
1. Install the air cleaner element. support bracket.
2. Install the upper housing. Make sure seal is in 5. Install fresh air inlet tube to air closure hose/filter
place. pack.
3. lighten upper air cleaner housing nuts to 2.3 N·m 6. Install air supply tube to engine air cleaner and
(20 Ib-in). Secure engine air cleaner duct tube retain with clamps. lighten clamps.
adapter to engine air cleaner. lighten to 1.5-2.5
N·m (13-22Ib-in).
ALL RIGHTS RESERVED
03·12·4 Air Intake 03·12·4
Air Cleaner Installation, F-150, F-250 and Bronco 5.0l Automatic and 5.8l California Engines (Except 5.8l
lightning)
A24044-A
Part Part
1 9B659 Air Cleaner Outlet Tube 11 9E926 Throttle Body
2 9B647 lower Air Cleaner Outlet 12 - Hose Clamp (Part of 9R504)
Tube A - Tighten to 2-3 N·m
3 - Hose Clamp (Part of 9B647) (18-27 lb-In)
4 9600 Engine Air Cleaner B - Use Water or Rubber
5 N611062-S2 Screw and Washer lubricant D9A2-19583-A or
Assembly (2 Required) Equivalent to Facilitate
Installation of Hose
6 16005 left Fender
Assembly to Throttle Body
7 N610958-S2 Screw (3 Required)
C - Surface Must Meet Against
8 9626 Engine Air Cleaner Mounting Throttle Body Stop Flange
Bracket for 360 0 (Both Tubes)
9 388577-S150 Pushpin (2 Required) 0 - Water Bottle Affixed at This
10 9C675 Fresh Air Intake Tube and location
Duct Assembly
(5.8l and 5.0)
(Continued)
ALL RIGHTS RESERVED
03-12-5 Air Intake 03-12-5
~ Engine Air Cleaner Installation, 5.8L Lightning
~
FRONT OF VEHICLE
Part Part
1 - Clamp, Air Cleaner Outlet 11 9626 Engine Air Cleaner Mounting
Tube Assembly Bracket
(Part of 9B659) A - Surface Must Meet Against
2 9B659 Air Cleaner Outlet Tube Throttle Body Stop Flange
3 18472 Heater Return Line for 360 0
4 9600 Engine Air Cleaner B - Tighten to 2-3 N·m
(18-27 Lb-In)
5 N611062-S2 Screw (2 Req'd)
6 17C431 Grommet (2 Req'd)
C - Fully Seat Outlet Tube
Against Cover Before Clamp
7 16005 Left Fender Is Tightened
8 N610958-S2
~
Screw (3 Req'd) 0 - Snap Heater Return Line into
9 9A675 Air Cleaner Intake Tube Clamps on Underside of
Assembly Outlet Tube Assembly
10 388577-S150 Pushpin, Nylon E - Water Bottle Affixed at This
Location
(Continued)
ALL RIGHTS RESERVED
03-12-6 Air Intake 03-12-6
Engine Air Cleaner In8tallatlon, F-150, F-250, F-350 4.9L Engine, California Automatic
A24045-A
Part Part
1 - Hose Clamp (Part of 9R504) 9 9626 Engine Air Cleaner Mounting
2 9B659 Air Cleaner Outlet Tube Bracket
3 9600 Engine Air Cleaner A - Hose Assembly Arrows Must
Be in Line with Locators on
4 N611062-S2 Screw and Washer Tap
Throttle Body
Assembly (2 Required)
5 16005 Left Fender
(9-18 Lb-In)
6 N610958-S2 Screw (3 Required)
C - Water Bottle Affixed at this
7 16138 Radiator Support Location
8 9A675 Fresh Air Intake Tube D - Surface Must Meet Against
Assembly Throttle Body Stop Flange
(Continued) for 360 0 (Both Tubes)
ALL RIGHTS RESERVED
03-12-7 Air Intake 03-12-7
,REMOVAL AND INSTALLATION (Continued)
Typical Engine Air Cleaner Installation, F-250 HD, F-350 and F-Super Duty Chassis Cab, 7.5L MFI Engine
3
10
FRONT OF VEHICLE
5 8
V5946-E
Part Part
1 9B659 Air Cleaner Outlet Tube 10 N610958-S2 Screw (4 Required)
2 N611062-S2 Tapscrew and Washer 11 17C431 Grommet (2 Required)
Assembly (2 Required) A - Hose Assembly Arrows Must
3 9600 Engine Air Cleaner Be in Line with Air Cleaner
4 16005 Left Fender Cover Arrows ± 2 0
6 16138 Radiator Support B - Water Bottle Affixed at This
Location
7 9A675 Fresh Air Intake Tube
Assembly C - Surface Must Meet Against
Throttle Body Stop Flange
8 9H308 Clamp for 360 0 (Both Tubes)
9 9626 Engine Air Cleaner Mounting 0 - Hose Assembly Arrows Must
Bracket Be in Line with Locators on
(Continued) Throttle Body ± 2 0
ALL RIGHTS RESERVED
03-12-8 Air Intake 03-12-8
Engine Air Cleaner Installation, F-Super Duty Motorhome Chassis, 7.5L MFI Engine
VIEW X
V7792·E
Part Part
1 9600 Engine Air Cleaner 10 N610958 Screw (2 Req'd)
2 N611062-S2 Screw 11 9C675 Air Inlet Tube Assembly
3 6853 Crankcase Ventilation Hose 12 17C431 Grommet Assembly
4 9H308 Idle Air Control Valve Inlet (2 Required)
Tube 13 - Clamp (Part of 9S449)
5 98659 Air Cleaner Outlet Tube 14 98458 Secondary Air Injection
6 - Crankcase Vent Pump Inlet Hose
(Part of 9H308) 15 9A486 Secondary Air Injection
7 388497-S 100 Clamp Pump
8 9J435 Secondary Air Injection 16 N610958-S2 Screw
Silencer Inlet Hose A - Tighten to 9-11 N·m
9 9647 Air Cleaner 8racket (80-97 Lb-In)
Assembly 8 - Tighten to 2-3 N·m
(18-27 Lb-In)
(Continued)
ALL RIGHTS RESERVED
03-12-9 Air Intake 03-12-9
Engine Air Cleaner Installation, 7.3L Direct Injection

Diesel Engine Part
6 N800889-S2 Nut and Washer
7 9600 Engine Air Cleaner Assembly
8 - Engine Air Cleaner Duct Tube
Adapter Clamp
(Part of 98676)
(62-80 Lb-In)
8 - Tighten to 23 N·m
(20 Lb-In)
(44-62 Lb-In)
Air Cleaner Outlet Tube, 7.3L Direct Injection

A23633-B Diesel Engine
Removal
Part 1. Loosen clamp retaining engine air cleaner duct
Item Number Description tube adapter (98676) to air cleaner assembly.
1 98676 Engine Air Cleaner Duct Tube 2. Loosen clamp retaining tube to turbocharger air
Adapter intake tube. Remove air cleaner duct.
2 - Nut (Part of 9600)
3 9N622 Restriction Gauge Installation
4 N800576-S2 Screw For installation procedures follow removal steps in
5 9A624 Engine Air Cleaner Intake reverse order. lighten clamp to 9-10 N·m (80-89Ib-in).
Tube
(Continued)
ALL RIGHTS RESERVED
03-12-10 Air Intake 03-12-10
Turbocharger Air Intake Tube Assembly
Y5248-A
Part Part
1 - Air Inlet Manifold Crossover 4 - Engine Air Cleaner Duct Tube
Pipe (Part of 6K682) Adapter Clamp
2 - Compressor Duct Clamp (Part of 98676)
(Part of 6K682) 5 98676 Engine Air Cleaner Duct Tube
3 - Compressor Duct Adapter
(Part of 6K682) 6 9600 Engine Air Cleaner
(Continued)
CLEANING AND INSPECTION SPECIFICATIONS
Air Inlet Restriction Check TORQUE SPECIFICATIONS

Remove air inlet tube as outlined, inspect for foreign Description N·m Lb-In
material and remove. Reinstall air inlet tube. 4.9L Engine 1-2 9-18
Clamp, Air Cleaner Outlet Tube
5.0 and 5.8L Engines 2-3 18-27
Clamp, Air Cleaner Outlet Tube
Air Cleaner Element 7.5L Engine 2-3 18-27
Inspect for foreign material, oil accumulation and Clamp, Air Cleaner Outlet Tube
distortion. Replace according to the schedule in 7.5L Engine, Motorhome Chassis 9-11 80-97
Section 00-03 or air restriction gauge for diesel. Screw, Air Cleaner to Bracket
Clamp, Secondary Air Injection 2-3 18-27
Silencer Inlet Hose
Clamp, Secondary Air Injection 2-3 18-27
Engine Air Cleaner Pump Inlet Hose
Remove particles and foreign debris from engine air Screw, Secondary Air Injection 9-11 80-97
cleaner, inspect assembly for cracks and wear; Body Bracket
replace if damaged. (Continued)
ALL RIGHTS RESERVED
03-12-11 Air Intake 03-12-11
TORQUE SPECIFICATIONS (Cont'd)

De8crlptlon H·m Lb·ln
7.3L 01 Diesel Engine 1.5-2.5 13-22
Clamp, Air Cleaner Duct Tube
Adapter
Screw, Air Cleaner Inlet Tube 7-9 62-80
Nut, Air Cleaner Cover 5-7 44-62

ALL RIGHTS RESERVED
03-13-1 Evaporative Emissions 03-13-1
SECTION 03-13 Evaporative Emissions

VEHICLE APPLICATION •••.••••••••••.•.•••••••••.••.•••••.••••••••• 03·13·1 DESCRIPTION AND OPERATION (Cont'd.)
DESCRIPTION AND OPERATION Fuel Tank Evaporative Emission System ...•••••.••..03·13·2
Fill Control/Vapor Vent System•••••••••••••••••••.•••••••••. 03·13·1 DIAGNOSIS AND TESTING
Fuel Vapor Canister ••.•••.••••••••..•••••••••••••..•.•••••...•..••03·13·2 Evaporative Emissions ••••••.••....••.•••••••••....••••••.••.•..03·13·6
Fuel Vapor Canister Purge Regulator Inspection and Verification ••.•••.•..•...•••••••.••.....••.••••03·13·6
Valve ••••••••••••••••••••••••••••••••.••.•••••••••...•••••••••...•.•••• 03·13·3 Pinpoint Test ••••••.•.•••.•.•••..•...•.••••••••••••...•••••••••.•••... 03·13·6
Fuel Vapor Emission Control System •••.•••.•.•••••.....•• 03·13·1 Symptom Chart•.••••••.•...•.••.••••••.•..•...•••••••.••...•••..••.•03·13·6
Fuel Vapor Hose •••••••••••••••••.••••••••.••...••••••••.•...•••.••. 03·13·3 REMOVAL AND INSTALLATION
Fuel Vapor Valve •••••••••.•••••••••••.•••••••••.•..••.•••••.•••..••• 03·13·5 Fuel Vapor Canister •...•••.•••••..•.....••...•••..•.....•..••••••.03·13·8
Fuel Vapor Valve, 5.8l MFI and 7.5l MFI Fuel Vapor Canister Purge Regulator
Engines •••••••••••••••••••••••••••••••••••••••.•••••••••••••.••.••••• 03·13·5 Valve •.•••.•...•••••••••.••.••••••••..•.•••.••••.•••••..•••••.••..••.•.03·13·8
Pressure and Vacuum Relief System •••••••..••.•••••••••• 03·13·5 Fuel Vapor Hose •••..•.•..•••.••••••••..•••.••••••.•••.•.•••..•.•••. 03·13·8
Fuel Tank Filler Cap ••••••••••••••••••••••••••••••••••••••.••.•• 03·13·5 Fuel Vapor Valve ••••.•••••.•••••.••..••.•••..•..•••.•••.••••.•.•••••03·13·8
System Components ••••.•••••••••••••••.••••••••.••.•.•••••••••• 03·13·2 SPECIFICATIONS ..•••••.••.•••••.••.••••.••...••.•••.••..•.••.••.•••03·13·21
Engine Evaporative Emission System •••••.•.•..•••••• 03·13·2 SPECIAL SERVICE TOOLS/EQUIPMENT •••...•.•.••••.••• 03·13·21
VEHICLE APPLICATION
F-Series and Bronco
Fuel Vapor Emission Control System

As a part of the fuel system, vehicles are equipped
with a fuel evaporative emission control system
designed to meet federal and state requirements in
effect at the time of production.
Fill Control/Vapor Vent System

Fill limiting is accomplished through fill pipe
configuration or external vent lines within the fuel tank
filler pipe (9034) and fuel tank (9002). The vent TO VAPOR
STORAGE
system is designed to permit at least 10 percent fuel
tank volume air space when the fuel tank is filled to FLOAT
capacity. This air space provides for thermal

expansion of fuel as well as being an aid to the in-tank
vapor vent system.
This system provides a vapor space above the
gasoline surface in the fuel tank. This area is sufficient
to permit adequate breathing space for the
evaporative emission valve (9B593) under static and
most dynamic conditions. This is accomplished by the
evaporative emission valve that is centrally located on
the upper surface of the fuel tank. TYPICAL SECTION
VAPOR VALVE ASSEMBLY WITH
All evaporative emission valves make use of a small FLOAT VALVE AND INTERNAL SPRING V1780-1E
orifice that tends to allow only vapor and not fuel to
pass into the line running forward to the evaporative Fuel vapors trapped in the sealed fuel tank are vented
emissions canister (EVAP canister)(9D653). On all through the orificed evaporative emission valve in the
vehicles, the assembly mounts directly to the top of top of the fuel tank. The vapors leave the evaporative
the fuel tank using a fuel vapor separator seal. emission valve through a single vapor line and continue
to the evaporative emissions canister for storage, until
they are purged to the engine (6007).
1995 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain July, 1994

ALL RIGHTS RESERVED
System Components • Evaporative emission canister valve (some

vehicles)
Fuel Tank Evaporative Emission System
• Evaporative emissions canister (some vehicles)
The evaporative emission system limits the amount of
fuel vapor a vehicle may release to the atmosphere, • Solenoid vent valve and purge regulator valve
enabling the vehicle to meet current federal and state (some vehicles)
requirements for fuel evaporation. • Secondary air bypass valve (some vehicles)
The following are components of the evaporative • Thermal vent valve (some vehicles)
emission system:
• Evaporative emissions canister
• Sealed fuel tank (9002) Not all of these components are used on anyone
• Fuel tank filler cap (9030) system, since usage depends on the calibration of the
complete vehicle.
• Evaporative emission valve (98593)
System control and operation are accomplished
• Evaporative emissions canister (EVAP through five separate basic functions in the system:
canister)(9D653)
1. Fill control venting.
• Evaporative emission canister valve (98963) (some
engines) 2. Tank vapor venting and storage system.
• Evaporative emission canister purge valve (EVAP 3. Fuel vapor return system.
canister purge valves)(9C915) (some engines) 4. Fuel vapor purge system.
The system works by capturing a very high 5. Pressure and vacuum relief system (fuel tank filler
percentage of fuel vapors that might otherwise cap and tank vent valve).
escape from the fuel tank. It then directs these vapors
to the evaporative emissions canister where they are
stored while the engine (6007) is not running. When
the engine is running, and conditions are acceptable,
the vapors are purged out of the evaporative Fuel Vapor Canister
emissions canister and into the engine. This "clears" Typical evaporative emissions canisters (EVAP
the evaporative emissions canister and allows it to canister)(9D653) are shown in the following
accept more fuel vapors the next time the engine is illustration. The evaporative emissions canister is
shut off. normally mounted in or near the engine compartment.
The system is basically the same for all vehicle and Two basic sizes are employed: 925ml or 1400ml. The
engine lines: a hose or tube runs from the fuel vapor "925" and" 1400" refer to volume of activated
valve at the top of the fuel tank to the evaporative carbon contained within the evaporative emissions
emissions canister to allow fuel vapors to pass from canister. Activated carbon is the working part of the
the tank to the evaporative emissions canister. A evaporative emissions canister. It has the unique
evaporative emission return tube (9G271) runs from ability to absorb (store) and purge (remove) fuel
the evaporative emissions canister to the engine, vapors by passing fresh air through the carbon bed. It
allowing vapors to be purged from the evaporative is able to do this over and over with almost no loss in
emissions canister. Some engines use additional ability to absorb and purge.
valves in one or more of these lines to provide Thus, all sources of fuel vapor (fuel tank (9002) and
additional control over how much or when fuel vapor purge control valve) are routed to the evaporative
will be allowed to pass. emissions canister for absorption of fuel vapor.
Engine Evaporative Emission System
This system consists of:

ALL RIGHTS RESERVED
Fuel Vapor Canisters, Typical Fuel Vapor Hose

The fuel vapor front hose transmits vapor from the
evaporative emission canister purge valve (EVAP
canister purge valves)(9C915) and evaporative
emission return tube (9G271) to the evaporative
emission canister purge valve.
Fuel Vapor Canister Purge Regulator Valve

SYMBOL
A typical evaporative emission canister purge valve
(EVAP canister purge valves)(9C915) is shown in the
~ following illustration. The evaporative emission
canister purge valve is located in the vapor line
EID between the evaporative emissions canister (EVAP
canister)(9D653) and the throttle body (9E926), and
CARBON is normally in the closed position until electrically
CANISTER energized.
The operation of the evaporative emission canister
purge valve is controlled by the powertrain control
module (PCM)( 12A650). When the engine (6007) is
off, the evaporative emission canister purge valve is
not energized and is in a closed, non-flowing condition.
When the engine is running, the powertrain control
module reads engine rpm, engine load, engine
temperature and other variables, and decides the
proper time for the engine to accept fuel vapors. When
this occurs, the powertrain control module energizes
the evaporative emission canister purge valve,
allowing flow from the evaporative emissions canister
to the intake manifold. The vapors are then consumed
in the engine. This action "purges" the evaporative
emissions canister of fuel vapors. It occurs as fresh air
is sucked into the evaporative emissions canister
under the fresh air inlet cap of the evaporative
emissions canister and through the activated carbon
Part bed. This allows the stored fuel vapors to pass from
Item Number Description the evaporative emissions canister through the
1 9A220 Fuel Vapor Line from Fuel
evaporative emission return tube (9G271) and the
Tank evaporative emission canister purge valve, and into
2 9G271 From Purge Control Valve
the engine.
3 90653 Evaporative Emissions
Canister 1400ml (1.48 Qts.)
4 - Fresh Air
5 90653 Evaporative Emissions
Canister 925ml (.98 ats.)

ALL RIGHTS RESERVED
03·13·4 Evaporative Emissions 03·13·4
Fuel Vapor Canister Purge Regulator Valve
CANISTER PURGE SOLENOID (CPRV) (·9C916-)

• USED WITH CLOSED LOOP
• NORMALLY CLOSED, SOLENOID VACUUM VALVE
• PURGES ON SIGNAL FROM ECA; USUALLY AT WARM
AND HOT CRUISE
@ VAPOR INLET
FROM CANISTER
CD VAPOR OUTLET
TO MANIFOLD FIITING
(OR PCV VALVE)
®VALVE
NORMALLY CLOSED (OPEN
TO FLOW WITH SOLENOID ON)
@ ELECTRICAL SIGNAL
FROM ECA ENERGIZES
SOLENOID
SYMBOL
CPRV
V5682·C
Fuel Vapor Valve, Typical
PURGE CONTROL VALVE OPERATION (PURGE CV) (-9B883-) SYMBOl.

• NORMALLY CLOSED
• OPENS VAPOR INLET TO PURGE OUTLET
wrTH VACUUM APPLED
REMOTE MOUNTED IN-UNE

TYPICAL PURGE VALVES V&&81-C

ALL RIGHTS RESERVED
Part Part
1 - Vapor Inlet Port (Connects to 5 - Diaphragm Is Normally Held
Fuel Vapor Canister) Closed by Spring
2 - Purge Outlet (Large) Port 6 - Carburetor 80wl Vent Port
(1 /4 Inch Nominal 0.0.) (Part of 98963)
Connects to Vacuum Source 7 - Vapor Inlet Port
3 - Signal Vacuum Port (Part of 98963)
(3/ 16 Inch Nominal 0.0.) 8 - Purge Port
Connects to Control Vacuum (Part of 98963)
Source 9 - Signal Vacuum Port
4 - Vapors Flow Out (Part of 98963)
(with Vacuum On)
(Continued)
Pressure and Vacuum Relief System Fuel Vapor Valve, 5.8L MFI and 7.5L MFI
Fuel Tank Filler Cap Engines
The fuel tank filler cap (9030) is sealed and includes a The evaporative emission valve (98593) mounted on
built-in pressure-vacuum relief valve. Fuel system the top of the fuel tank (9002) is used to control the
vacuum relief is provided after 3.5 kPa (0.50 psi) and flow of fuel vapor entering the fuel tank vapor delivery
pressure relief after 11.0 kPa (1.6 psi). Under normal line which conducts vapor forward to the evaporative
operating conditions, the fuel tank filler cap operates emissions canister (EVAP canister)(9D653) in normal
as a check valve, allowing air to enter the tank as fuel circumstances. If, due to extreme conditions,
is used, while preventing vapors from escaping the excessive pressure is generated inside the tank, the
tank through the cap. purge port opens up, allowing fuel vapor to escape to
the atmosphere, and stabilizes pressure inside the fuel
NOTE: Use of an aftermarket fuel tank filler cap other tank. The evaporative emission valve has a head valve
than an authorized Ford / Motorcraft service part could which prevents the fuel tank from overfilling during
result in damage to the fuel system or improper refueling operation. The evaporative emission valve
system operation if not properly also has a spring supported float assembly, which
designed / manufactured for pressure-vacuum relief. prevents liquid fuel from entering the vapor delivery
Customer warranty is void for fuel tank or fuel system line during severe handling, steep grades or in the
damage resulting from the use of such caps. event of vehicle rollover.
Fuel Vapor Valve
Fuel Vapor Valve HEAD

VALVE
The evaporative emission canister valve (98963) is in
line with the evaporative emissions canister (EVAP
canister)(9D653) and controls the flow of fuel vapors
out of the evaporative emissions canister. It is a
TO VAPOR
normally closed valve that opens with vacuum input. TO STORAGE
Operation of the evaporative emission canister valve ATMOSPHERE
is shown in the following illustration. Also shown are
views of typical evaporative emission canister valves.
V747G-1A
ALL RIGHTS RESERVED
Evaporative Emissions
1
Manual for individual components.
Inspection and Verification 3. If the concern(s) is verified by the inspection,

1. Verify the vehicle owner's original concern by determine the symptoms and proceed to the
removing fu~1 tank filler cap (9030) to duplicate following Symptom Chart.
the condition.
2. Inspect to determine if any of the following
mechanical concerns apply:
Mechanical
• Hissing sound or release of pressure as the fuel tank filler
cap is removed from the fuel tank filler pipe.
Symptom Chart
EVAPORATIVE EMISSIONS
• Abnormal Pressure in Fuel Tank • Evaporative emission hoses or
inlets blocked.
• GO to Pinpoint Test A.
• Tubes or hoses kinked or pinched.
Pinpoint Test
PINPOINT TEST A: FUEL TANK PRESSURE ABNORMAL
A1 I CANISTER HOSE AND INLET TUBE BLOCKAGE TEST
• Test canister fuel vapor hose and inlet nipple for
blockage.
Yes
No
~ GOtoA2.
~ GO to A6.
I•TEST
Are fuel vapor h08e8 or Inlet blocked?
A2 FUEL EVAPORATIVE EMISSION SYSTEM BLOCKAGE
• Test fuel tank evaporative emission system for

blockage.
Yes ~ REMOVE blockage or
REPLACE component.
• Are all 8Y8tem pa88age8 open? No ~ GOtoA7.
A3 I VAPOR TUBE INSPECTION
~ SERVICE or REPLACE
• Inspect vapor tube and fuel vapor hoses for kinks or
pinched areas.
Yes
tube or fuel vapor hoses.
• Are tube or fuel vapor h08e8 kinked or pinched?
No
VERIFY service.
~ GOtoA4.
A4 I VAPOR HOSE INSPECTION
• Inspect vapor hose routing between fuel tank and
body for pinch.
Yes ~ LOOSEN fuel tank and
REROUTE hose. VERIFY
• 18 vapor h08e pinched?
No
service.
~ GO to AS.

1995 F-150, F-250, F-350, Bronco. F-Super Duty Powertrain. Drivetrain July, 1994

ALL RIGHTS RESERVED
03-13-7 Evaporative Emissions 03·13·7
PINPOINT TEST A: FUEL TANK PRESSURE ABNORMAL (Continued)

A5 FUEL VAPOR VALVE INSPECTION
• Remove fuel tank. Yes ~ INSTALL evaporative
• Remove evaporative emission valve. emission valve in fuel
• Inspect evaporative emission valve for open air tank. INSTALL fuel tank.
passage through orifice. System test complete.
• Is air passage open? No ~ REPLACE evaporative
emission valve. VERIFY
service.
A6 FLOW TEST (FUEL TANK FILLER CAP INSTALLED)
CAUTION: Do not use other high pressure air Yes ~ System flow OK. GO to
supplies. Will result In damage to evaporative A2.
emissions canister. No ~ PERFORM Pinpoint Test
• Install hand pump and pressure gauge Rotunda StepA3.
Vacuum Tester 021-00014 or equivalent in fuel
vapor hose at test point 81.
• Hand pump to a maximum of 17.2 kPa (2.5 psi).
• Does pressure drop to zero Immediately?
A7 FLOW TEST (FUEL TANK FILLER CAP REMOVED)
CAUTION: Failure to remove fuel tank filler cap may Yes ~ System OK, no service
result In damage to fuel tank. required.
• Remove fuel tank filler cap from fuel tank filler pipe. No ~ PERFORM Pinpoint Test
StepA4.
CAUTION: Do not use other high-pressure air
supplies. Damage to fuel tank may result.
• Install hand pump and pressure gauge onto tee or
fuel vapor canister nipple at test point 82.
• Hand pump to a maximum of 17.2 kPa (2.5 psi).
• Does pressure drop to zero Immediately?
A23682·A
Part
1 - Test Point B2 with Tee
2 - Test Point B 1 with Tee
3 - Test Point B2 Without Tee
4 90653 Evaporative Emissions Canister
5 - Test Point B1 Without Tee
6 - Close Off Line
7 - To Fuel Tank
8 9G271 Vapor Tube
9 9G297 Vapor Hose

ALL RIGHTS RESERVED
WARNING: THE EVAPORATIVE EMISSION Fuel Vapor Hose

SYSTEM CONTAINS FUEL VAPOR AND
Removal
CONDENSED FUEL VAPOR. ALTHOUGH NOT
PRESENT IN LARGE QUANTITIES, IT STILL 1. Disconnect the hose clamps from both ends of
PRESENTS THE DANGER OF EXPLOSION OR the evaporative emission hose (9G297) to be
FIRE. DISCONNECT THE BATTERY GROUND removed.
CABLE (14301) FROM THE BATTERY TO 2. Remove the evaporative emission hose from the
MINIMIZE THE POSSIBILITY OF AN ELECTRICAL component. Do not pull on the evaporative
SPARK OCCURRING, POSSIBLY CAUSING A FIRE emission hose without firmly holding the
OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL component in place.
ARE PRESENT IN THE AREA.
3. Disconnect the evaporative emission hose from
CAUTION: Fuel supply lines on vehicles with fuel all retainers and remove the evaporative emission
injected engines (6007) will remain pressurized hose.
for long periods of time after engine shutdown.
The pressure must be relieved before servicing Installation
the fuel system. Refer to fuel system pressure NOTE: When replacing the evaporative emission
relief. For servicing information on fuel lines refer hose, use original equipment size and length.
to Section 10-01 A.
To install, reverse the procedure for removal.
Evaporative emissions systems have been designed
and tested to exceed 193,080 km (120,000 miles) or Inspect the evaporative emission hose and adjust it to
10 years of vehicle use. No maintenance or service remove any crimps and restrictions.
should be required. However, if components have
been damaged and need to be replaced, or there is a
need to remove and reinstall or disconnect
components for other reasons, such as diagnosis, Fuel Vapor Canister Purge Regulator Valve
refer to the following procedures and illustrations to
aid in servicing the system. Removal and Installation
Evaporative emission systems are shown in the 1. Disconnect wire harness from evaporative
illustrations that follow. Refer to these illustrations for emission canister purge valve (EVAP canister
component location and installation instructions. purge valves)(9C915).
Use Ford-approved parts for replacement of fuel and 2. Disconnect fuel vapor hoses from evaporative
vapor hoses and tubes. Original equipment emission canister purge valve and remove
components are designed to resist most evaporative emission canister purge valve.
environmental conditions encountered in the 3. To install, reverse removal procedure.
evaporative emission system.
Fuel Vapor Valve

Fuel Vapor Canister Refer to Section 10-0 1A.
Refer to the appropriate illustration for component
location.
1. Disconnect vapor hoses from evaporative
emissions canister (EVAP canister)(9D653) to be
removed.
2. Remove screw retaining evaporative emissions
canister to fuel bracket (9D664) or fender apron.
3. Lift evaporative emissions canister to disengage
tab on back side of evaporative emissions
canister, and remove evaporative emissions
canister.
For installation, follow removal steps in reverse order.
lighten retaining screw to 5-7N·m (44-62Ib-in).

ALL RIGHTS RESERVED
Vapor Lines, F-Series, Short Wheelbase
-
FRONT OF VEHICLE
RIC AND SIC SWB

REGULAR CAB SHOWN
DUAL TANK
REGULAR CAB SWB

AFT AXLE TANK A17885·A
Part Part
1 9002 Fuel Tank, Aft of Axle 5 9C016 Vapor Return Tube and Hose
2 9C987 Evaporative Valve Assembly Assembly
3 9002 Fuel Tank, Midship 6 9A317 Fuel Tube Clip
4 98227 Evaporative Hose and Valve
Assembly
(Continued)

ALL RIGHTS RESERVED
Vapor Lines, F-Series, Long Wheelbase
..
FRONT OF
VEHICLE
REGULAR CAB LWB

AFT AXLE TANK
A17886-C
Part Part
1 9A317 Fuel Tube Clip 3 9C987 Evaporative Valve Assembly
2 9C016 Vapor Return Tube an.d Hose 4 9002 Fuel Tank
Assembly
(Continued)

ALL RIGHTS RESERVED
Vapor Lines, F-Series Chassis Cab
. .
CHASSIS CAB. SINGLE TANK
UNDER 8500 GVW, LWB SHOWN
CHASSIS CAB, DUAL TANKS

UNDER 8500 GVW, LWB SHOWN
CHASSIS CAB OVER 8500 LB GVW SHOWN
VIEW A
A17887-C
Part Part
1 9C016 Vapor Return Tube and Hose 3 9C987 Evaporative Valve Assembly
Assembly
2 9002 Fuel Tank
(Continued)

ALL RIGHTS RESERVED
Vapor Lines, Bronco
VlEWB
A17888-C
Part Part
1 9C015 Vapor Tube and Hose 4 9C016 Vapor Tube and Hose
Assembly Assembly
2 9C987 Evaporative Valve Assembly 5 90653 Evaporative Emissions
3 9002 Fuel Tank Canister
(Continued)

ALL RIGHTS RESERVED
03-13-13 Evaporative Emissions 03-13·13
Engine Vapor Lines, F-Series, 4.9L
•
FRONT OF VEtlCLE
•
FRONT OF ENGINE
VIEW A
Part Part
1 9G321 Fuel Vapor Return Hose 6 9A220 Fuel Vapor Return Hose
2 9G271 Fuel Vapor Return Tube Assembly
3 - I=uel Tank Vapor Line 7 10655 Battery
(Part of 9A220) 8 16054 Front Fender Apron
4 N800639-S2 Screw A - Tighten to 5-7 N·m
5 90653 Evaporative Emissions (44-62 Lb-In)
Canister
(Continued)

ALL RIGHTS RESERVED
Engine Vapor Lines, F-Serles and Bronco, 5.0L
~
FRONT OF VEHICLE
""....-._------~6
..
VlEWB
VIEW A VlEWB
A18221
Part Part
1 9C987 Hose and Valve Assembly - 3 - Hose (Purge
Fuel Vapor Return Valve-to-Throttle Body,
2 9C915 Fuel Vapor Purge Valve Part of 9C987)
Assembly 4 9E926 Throttle Body

ALL RIGHTS RESERVED
Part Part
5 90653 Evaporative Emissions 10 9G271 Evaporative Emission Return
Canister Tube
6 - Fender Apron 11 90664 Fuel Bracket
7 9A220 Connector Assembly - Fuel A - Tighten to 5-7 N·m
Vapor Return (44-62 Lb-In)
8 N800369-S2 Screw, M6.3-1.81 x 16 B - Route on Fender Side of
9 9C016 Evaporative Tube (Refer to Secondary Air Injection
Fuel Line Installation Supply Pump Inlet Hose
Illustrations in This Section)
(Continued)
Engine Vapor lines, F-Serles and Bronco, S.al (Except S.al lightning)
....
VIEWS
•
FRONT OF ENGINE
VIEW A
FRONT OF ENGINE
•
FRONT OF VEHICLE
VIEWS • A17891-B
Part Part
1 9C987 Fuel Vapor Return Hose and 5 10A812 Battery Tray Support
Valve Assembly 6 9E926 Throttle Body
2 90653 Evaporative Emissions 7 12A581 Wiring Assembly
Canister A - Tighten to 5-7 N·m
3 N800369-S2 Screw, M6.3 x 1.81 x 16.0 (44-62 Lb-In)
4 9A220 Fuel Vapor Return Hose
Assembly
(Continued)
1995 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain July. 1994

ALL RIGHTS RESERVED
Engine Vapor lines, 5.8l lightning
FRONT OF ENGINE
.. VIEW A
FRONT OF VEHICLE
~
FRONT OF ENGINE
VIEWB ~
A19021-B
Part Part
1 9C987 Fuel Vapor Return Hose and 5 9C016 Fuel Tank Vapor Line
Valve Assembly Assembly
2 90653 Evaporative Emissions 6 - Pushpin (for Fender Apron
Canister Mounting) (Part of 9A220)
3 N800369-S2 Screw, M6.3x 1.81 x 16 7 10723 Battery Tray
4 9A220 Fuel Vapor Return Hose Line 8 10A812 Battery Tray Support
Assembly A - Tighten to 5-7 N·m
(Continued) (44-62 Lb-In)

ALL RIGHTS RESERVED
Engine Vapor Lines, F-250, F-350, 5.8L, Over 8500 GVW, Under 8500 GVW Similar
c=:::J
HOSE ROU11NG
UNDER 8500 GVW
VIEW A
HOSE FIOU11NG OVER ~.~~

8500GVW
VIEWS VlEWC
ALL RIGHTS RESERVED
Part Part
1 9C987 Hose and Valve Assembly, 5 N800369-S2 Screw
Fuel Vapor Return 6 9A220 Connector Assembly, Fuel
2 9C016 Fuel Tank Vapor Line Vapor Return
3 10732 Battery Tray 7 9E926 Throttle Body
4 90653 Evaporative Emissions A - Tighten to 5-7 N·m
Canister (44-62 Lb-In)
(Continued)
ALL RIGHTS RESERVED
Engine Vapor Lines, F-250, F-350, 7.5L
..
FRONT OF VEHICLE
.,
FRONT OF VEHICLE
4x4
VIEW A
FRONT OF VEHICLE
• FRONT OF ENGINE
~
A17892-C
Part Part
1 9C98? Fuel Vapor Return Hose And 3 9G297 Evaporative Emission Hose
Valve Assembly 4 N800369-S2 Screw, M6.3 x 1.81 x 16.0
2 90653 Evaporative Emissions 5 N620481-S2 Nut, M8 x 1.25
Canister 6 5005 Frame

ALL RIGHTS RESERVED
Part Part
7 90664 Fuel Bracket (4x4 Vehicles) 11 - Reinforcement Assembly
8 N605786-S2 Bolt. M8 x 1.25 x 20 Right Fender Apron
W611635-S2 Screw. M8 x 1.25 x 20 (Part of 10A812)
9
10 90664 Fuel Bracket (4x2 Vehicles) A - Tighten to 5-7 N·m
(44-62 Lb-In)
(Continued) B - Tighten to 20-30 N·m
(15-22 Lb-Ft)
Engine Vapor Lines, F-Super Duty, 7.5L
FRONT OF ENGINE
~
VIEW A
•
FRONT OF VEHICLE
•
VIEW 8
FRONT OF VBlCLE
• VlEWB
A17893-C
Part Part
1 9C987 Fuel Vapor Return Hose And 5 N800369-S2 Screw, M6.3x 16.0
Valve Assembly 6 90664 Fuel Bracket
2 9G247 Fuel Tank Vapor Line 7 W611635-S2 Screw, M8 x 1.25 x 20
3 90653 Evaporative Emissions 8 5005 Frame (Reference)
Canister 9 9A220 Right Fender Apron
4 9G297 Evaporative Emission Hose 10 10655 Battery

ALL RIGHTS RESERVED
Part
(44-62 Lb-In)
SPECIFICATIONS SPECIAL SERVICE TOOLS/EQUIPMENT

Description N·m Lb-Ft Lb-In I Model I Description I
Fuel Vapor Canister to Fuel 5-7 - 44-62 I 021-00014 I Vacuum Tester I
Bracket
Fuel Bracket to Frame 4x2 5-7 - 44-62
Fuel Vapor Canister to Front 5-7 - 44-62
Fend~r Apron
Fuel Bracket Bolt to Frame 4x4 20-30 15-22 -

ALL RIGHTS RESERVED
03-14-1 Engine Controls, Electronic 03-14-1
SECTION 03·14 Engine Controls, Electronic

VEHICLE APPLICATION •••......••••••••••......••••.•.......•••.•.•03-14-1 REMOVAL AND INSTALLATION (Cont'd.)
DESCRIPTION AND OPERATION R.moval and Installation ••••••.•...•.•..•••••••••••••.•03·14·14
Accelerator Pedal (AP) Position Sensor...........•......03-14-3 Engln. 011 T.mp.ratur. (EOT) S.nsor •..•••••••••••••••03-14·15
Barometric Pressure (BARO) Sensor ..•••••••••..•.•••••••03-14-5 Exhaust Back Pressure (ESP) Sensor ••••••.......••••.•03·14·19
Camshaft Position (CMP) Sensor .................•...•.••...03-14-7 Exhaust Back Pressure R.gulator (EPR) •••••••••••••••03·14·19
Engine Control Systems, Electronic ......•••.••.....•.....03-14-1 H.at.d Oxyg.n S.nsor (H02S) ••••••••••••••••••••••••••••03-14-18
Engine Coolant Temperature (ECT) Idl. Air Control (lAC) Valv•••••.••••••••••..•.•.•......•.••••.03·14·12
Sensor ...................................................••...•......03-14-5 Idl. Validation Switch (IVS) ••••••••••••.••••.••••••••••••••••03·14·10
Engine 011 Temperature (EOT) Sensor ....•.....•.••.••.•.03-14-4 Inj.ctlon Control Pr.ssur. (ICP) S.nsor ..•••••••..•.••03-14·17
Exhaust Back Pressure (ESP) S.nsor ...•......•...•.•••.•03-14-5 Inj.ctlon Control Pr.ssur. R.gulator ..•.....•....••.•.•03·14·17
Exhaust Back Pr.,sur. R.gulator (EPR) ..........•..•...03-14-6 Inj.ctor Drlv.r Module (IDM) ••..••••••••••••.•••.•••.•.••••..03-14-10
H.at.d Oxyg.n S.nsor (H02S) •••••...•.••••••••••....••••••03-14-6 Intak. Air T.mp.rature (IAT) S.nsor.••••...••••••••••.••03-14·10
Idl. Air Control (lAC) Valv•............•..•..••••.•.•••..••••.••03-14-4 Intake Air T.mperatur. (IAT) S.nsor••••••••.........•...03-14-12
Idle Validation Switch (IVS) ••••••••••••...••••••••••••.••.•••••03-14-3 Knock S.nsor (KS)•........•..•••••..•.•...••..••••••••••••••••••03-14-29
Inj.ctlon Control Pr.ssur. (ICP) S.nsor .......••.•.••••.03-14-6 Manifold Absolut. Pr.ssur. (MAP) ,
Inj.ctlon Pressure Regulator (lPR) •••.•..•••••••••••••.•••••03-14-6 Sensor •.•.•••••••••.••.•••.......•...••••••••••••..••••......••.•••03-14·16
Inj.ctor Driver Module (IDM) ...••••••.......••••••••.••.••.••••03-14-2 Manifold Absolute Pr.ssure (MAP) Sensor (MFI
Intak. Air Temp.ratur. (IAT) S.nsor••••.•..•..•••••••••...03-14-3 Gasolln. Engines Only)•••••••••••••••••••••••••••••••••••••03-14·16
Knock S.nsor (KS)..•••........••............•.•............•.•....O3-14-7 Mass Airflow (MAF) Sensor ..•.•••••••••..••••••••.••••••.•••03-14·10
Manifold Absolut. Pr.ssur. (MAP) S.nsor •........•••••03-14-5 Pow.rtraln Control Module (PCM) •••••••••••••••••••••••••• 03-14~8
Mass Airflow (MAF) S.nsor ••••••••••••••••.••••••......•••••••03-14-3 Saf.guards•.••...••...•....•.•••••.••••••••...••••...•••••••••••••••••03·14-8
Powertraln Control Modul. (PCM) ..••.•••••••.•.....•.....•03-14·2 Throttle Position (TP) S.nsor ••••••••••••.••..••......•.••..••03-14-8
Throttl. Position (TP) S.nsor .•••••••.....•••••••••...••.•••••03·14-2 V.hlcl. Sp••d Sensor (VSS) ••••••.•••.•••••..•••••••••.•••••03-14·20
V.hlcl. Sp••d S.nsor (VSS) •........•••.•.......•...•.••....•.03-14·7 CLEANING AND INSPECTION
DIAGNOSIS AND TESTING Idl. Air Control Valv•.•......•••...••••••••••.••.•..••.....•••••03·14·21
Engln. Controls, EI.ctronlc •••••.......•..•......••..••••.•...03-14·7 Alt.rnat. CI.anlng Proc.dur•••••••.••••••••••..•.••••••03··14-21
REMOVAL AND INSTALLATION ADJUSTMENTS ·
Acc.l.rator P.dal (AP) Position Sensor •.•...•....•.•••••03-14-9 Acc.l.rator P.dal (AP) Position Sensor ••••••••••••.•••03·14·21
Barom.trlc Pr.ssur. (BARO) S.nsor ...•......•....••...03·14-16 Throttle Position (TP) S.nsor .••••••••.•••••••.•.••.••••••••03·14·21
Camshaft Position (CMP) S.nsor •••.••.•.••••••••.••.••.••03·14-19 SPECIFICATIONS •••••••.•••••••..•••••..••••••••••••••••.••...••••••03-14-21
Engine Coolant T.mp.ratur. (ECT) SPECIAL SERVICE TOOLS/EQUIPMENT ...•.•••••••.•••••03-14·22 . )
S.nsor ••......•••••.••....••••••••••.....••••••••........•••••••...03-14-14
VEHICLE APPLICATION
F-150, F-250, F-350, F-Super Duty Series and Bronco
Vehicles
WARNING: DO NOT SMOKE, CARRY LIGHTED

TOBACCO, OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL RELATED
COMPONENT. HIGHLY FLAMMABLE MIXTURES
ARE ALWAYS PRESENT AND MAY BE IGNITED,
RESULTING IN POSSIBLE PERSONAL INJURY.
Engine Control Systems, Electronic The multiport fuel injection SFI system (on all 5.0l
automatic vehicles and California 4.9l and 5.8l
Gasoline Engines vehicles) is classified as a multi-point, pulse time,
The multiport fuel injection MFI system is classified as mass airflow, sequential fuel injection system.
a multi-point, pulse time, speed density, fuel injection
system. Diesel Engine
The 7.3l Diesel Engine is classified as a multi-point,
pulse time, speed density fuel injection system.

ALL RIGHTS RESERVED
To maintain the required exhaust emission levels, the

fuel metering system must be in proper operating
condition and adjusted to the specifications listed
in / on the following sources:
• The applicable section of the Powertrain
Control/Emissions Diagnosis Manual. 1
• The applicable section of this Group.
• The Vehicle Emission Control Information (VECI)
decal.
Additional engine performance checks are required to
keep the exhaust emissions at the specified minimum
POWERTRAIN CONTROL
pollutant level. Refer to Section 00-03 for these MODULE-12A650
performance checks and their recommended A20789-A
intervals.
Always refer to the Master Parts List for parts usage
and interchangeability before replacing any
emissions-related components. Throttle Position (TP) Sensor
Always refer to the Master Parts List for parts usage
and interchangeability before replacing a throttle body Gasoline Engines
(9E926) or any component part of a throttle body. The throttle position sensor (TP sensor)(9B989) is a
potentiometer that provides a signal to the powertrain
control module (PCM)( 12A650) proportional to the
throttle plate position. The throttle position sensor
Powertrain Control Module (PCM) connects to the throttle plate shaft.
The powertrain control module (PCMX 12A650)
receives inputs from various engine sensors to
compute the required fuel flow rate necessary to
maintain a proper air / fuel ratio throughout the entire
engine operational range.
compensates the vehicles uniqueness. The system will
also compensate for changes in altitude (Le., from sea
level to mountains).
Gasoline Engines
The 60 pin EEe-IV system powertrain control module
outputs a command to the fuel injector to meter the
appropriate quantity of fuel.
Diesel Engine
The 104 pin EEC-V system powertrain control module
outputs a command to the injector driver module (10M)
which in turn energizes the fuel injector with up to Injector Driver Module (10M)
115V DC. The fuel injector is controlled by the injector
driver module (10M) to meter the appropriate quantity Diesel Engine
of fuel at the correct time and duration. The injector driver module (10M) supplies 115V OC to
all of the fuel injectors.
The injector driver module (10M) receives signals from
the powertrain control module for cylinder
identification and fuel delivery command signal
(FDCS). The powertrain control module controls when
the timing of the injectors should start and how long
the injector is open.
The 10M controls the injector firing sequence through
output drivers. The 10M has an output driver for each
injector: one low side driver for each injector and one
high side driver for each bank of injectors. The
injector is fired when the output driver closes the
circuit to ground, completing the circuit ground path.


ALL RIGHTS RESERVED
Accelerator Pedal (AP) Position Sensor CAUTION: Sensing elements located in the mass
airflow sensor should not be tampered with or
Diesel Engine cleaned.
The accelerator pedal (AP) position sensor is a
potentiometer that provides a signal to the powertrain
control module (PCM) proportional to the accelerator
pedal position. The accelerator pedal (AP) position
sensor connects to the accelerator pedal shaft.
A24037-A
A23697-A Part
1 - MAFS Electronics Module
(Part of 12B579)
Idle Validation Switch (IVS) 2 - MAFS Body (Part of 12B579)
Diesel Engine 3 - Airflow Bypass (Part of
12B579)
The idle validation switch (IVS) provides the
powertrain control module (PCM) with a redundant
signal to verify when the accelerator pedal and shaft is
in the idle position. Any detected malfunction of the idle
validation switch (IVS) will illuminate the "Check Intake Air Temperature (IAT) Sensor
Engine" light and the engine will operate at low idle Gasoline and Diesel Engines
only.
The intake air temperature sensor (IAT
sensor)( 12A697) changes resistance in response to
changing intake air temperature. The IAT sensor
resistance decreases as the air temperature
Mass Airflow (MAF) Sensor increases providing a signal to the powertrain control
Gasoline Engines module (PCM)( 12A650) indicating temperature of the
incoming intake air. On diesel engines, the IAT sensor
The mass air flow sensor (MAF sensor)( 128579) is is installed in the lower intake manifold on MFI engines
located between the engine air cleaner (ACL)(9600) and in the air cleaner tube on SFI engines.
and the throttle body (9E926). The mass air flow
sensor uses a hot wire sensing element to measure
the amount of air entering the engine. Air passing over INTAKE AIR TEMPERATURE SENSOR
12A697
the hot wire causes it to cool. The mass air flow
sensor then outputs an ~nalog voltage signal to the
powertrain control module (PCM)( 12A650) to
determine the intake air mass. The powertrain control
module will calculate the required fuel injector pulse
width in order to provide the desired air /fuel ratio.
The mass airflow sensor electronics module A20792-A
body element and housing are calibrated as a unit
and must be serviced as a complete assembly.
ALL RIGHTS RESERVED
03-14-4 Engine Controls, Electronic 03-14·4
Engine Oil Temperature (EOT) Sensor

ELECTRICAL
Diesel Engine CONNECTOR
The engine oil temperature sensor (EOT sensor)
changes resistance in response to changing
temperature of the engine oil. The engine oil
temperature sensor resistance decreases as the ENGINE OIL
engine oil temperature increases providing a signal to '----......-- TEMPERATURE
the powertrain control module (PCM), indicating the SENSOR
temperature of the engine oil. A23692-A
Idle Air Control (lAC) Valve CAUTION: Use of unapproved solvents may
damage the lAC valve.
Gasoline Engines
The idle air control valve (lAC valveX9F715) is used to
control engine idle speed and dashpot functions. The
idle air control valve is mounted on the throttle body
(9E926) and allows air to bypass the throttle plate.
The amount of air allowed to bypass the throttle plate,
will be determined by the powertrain control module
(PCM)(12A650) and will be controlled by a duty cycle
signal.
Idle Air Control Valve Assembly, Cleanable
VALVE
BODY
INLET
(ATMOSPHERE)
Idle Air Control Valve Assembly, Non-Cleanable
DIAPHRAGM
RUBBER
DAMPENER
S.OL SHOWN AIR FLOW INLET

•I •I tAIR FLOW OUTLET
A2133S-B
ALL RIGHTS RESERVED
Engine Coolant Temperature (ECT) Sensor Barometric Pressure (BARO) Sensor

Gasoline Engines Diesel Engine
The engine coolant temperature sensor (ECT The barometric pressure sensor (BARO sensor) is a
sensor)( 12A648) changes resistance in response to variable capacitance sensor that, when supplied with
changing temperature of the engine coolant. The a 5 volt reference signal from the powertrain control
engine coolant temperature sensor resistance module (PCM), produces an analog voltage that
decreases as the engine coolant temperature indicates barometric pressure. The sensor signal is
increases providing a signal to the powertrain control used to determine altitude to adjust timing and quantity
module (PCM)(12A650) indicating the temperature.of of fuel to optimize engine operation. The output of the
the engine coolant. barometric pressure sensor is one of the variables
used to calculate glow plug on time.
ELECTRICAL
CONNECTOR BAROMETRIC
PRESSURE
(BARO)
SENSOR
ENGINE COOLANT
TEMPERATURE
SENSOR ------..~~
12A648
A20793-B
Manifold Absolute Pressure (MAP) Sensor

Gasoline and Diesel Engines A23332·A
The manifold absolute pressure sensor (MAP
sensor)(9F479) is used on some applications. The
MAP sensor measures the pressure in the intake
manifold (9424) and provides this information as a Exhaust Back Pressure (EBP) Sensor
variable frequency signal to the powertrain control Diesel Engine
module (PCMX12A650). With the Ignition Switch in the
KEY ON/ENGINE OFF position, the manifold absolute The exhaust back pressure (EBP) sensor is a variable
pressure sensor will indicate the barometric pressure capacitance sensor that, when supplied with a 5 volt
in the intake manifold. The MAP sensor is used to reference signal from the power control module
indicate boost pressure on the diesel engine. This (PCM), produces a linear analog voltage signal that
sensor is not required on 4.9L engines with California indicates exhaust back pressure.
emissions using E40D transmissions. The powertrain control module uses this signal to
control the exhaust back pressure device when
MANIFOLD ABSOLUTE PRESSURE needed.
(GREY FOR DIES~E__
L)_ _1IIIllIlllo.
SENSOR
9F479
EXHAUST
BACK
PRESSURE
SENSOR
INTAKE
MANIFOLD
VENT
A20794-B
A22285-A
1995 F-150, F-250, F-350, Bronco, F-Super Duty powertrain, Drivetrain July 1994
ALL RIGHTS RESERVED
Exhaust Back Pressure Regulator (EPR) Injection Pressure Regulator (IPR)

Diesel Engine Diesel Engine
The exhaust back pressure regulator (EPR) is a The injection pressure regulator (IPR) is a
variable-position valve that controls exhaust back variable-position valve that controls injection control
pressure during cold ambient temperatures to pressure. Battery voltage is supplied to the injection
decrease the amount of time required to warm up the pressure regulator when the ignition switch is in the
engine. The powertrain control module ON position. Valve position is controlled by switching
(PCM)( 12A650) uses the measured exhaust back the output signal circuit to ground inside the powertrain
pressure, ambient air temperature and engine oil control module (PCM)( 12A650). Injection pressure is
temperature to determine the desired exhaust back controlled by the powertrain control module based on
pressure. inputs from intake air temperature, engine oil
temperature, manifold and barometric pressure, and
pedal position.
EXHAUST
BACK
PRESSURE~
SOLENOID· ~
VALVE
INJECTION
PRESSURE
REGULATOR (IPR)
A22289-A
A22288-B
Heated Oxygen Sensor (H02S)
Gasoline Engines
Injection Control Pressure (ICP) Sensor The heated oxygen sensors (H02S)(9F472) react
with the oxygen in the exhaust gases and will generate
Diesel Engine a voltage. A low voltage indicates too much oxygen or
The injection control pressure (ICP) sensor is a a lean condition. A high voltage indicates not enough
variable capacitance sensor that, when supplied with oxygen or a rich condition. The heated oxygen
a 5 volt reference signal from the powertrain control sensors are located in the exhaust pipes below the
module (PCMX12A650), produces a linear analog exhaust manifolds on 49 state. Two heated oxygen
voltage signal that indicates oil pressure. The ICP sensors are located in the exhaust manifolds on 4.9L,
sensor provides a feedback signal to indicate high California emissions and E40D.
pressure oil so that the powertrain control module can
command the correct injector timing, pulse width and
injection control pressure for proper fuel delivery at all HEATED OXYGEN
SENSOR (H02S)
speed and load conditions. 9F472
INJECTION A20795-B
CONTROL
PRESSURE
(Iep)
SENSOR
A22286-A

ALL RIGHTS RESERVED
Camshaft Position (CMP) Sensor Vehicle Speed Sensor (VSS)

The camshaft position sensor (CMP sensor) is a The vehicle speed sensor (VSS) provides the
Hall-effect type sensor that generates a digital Programmable Speedometer / Odometer Module with
frequency while windows in a target wheel pass an indication of vehicle speed.
through its magnetic field. The frequency of the This input is used in determining transmission shift
windows passing by the sensor, as well as the width of scheduling and electronic pressure control.
selected windows, allows the powertrain control
module (PCM)( 12A650) (PCM) to detect engine speed
and position. VEHICLE
SPEED
CAMSHAFT POSITION SENSOR
SENSOR
Engine Controls, Electronic

A23333-A Gasoline Engines (EEC-IV)
Manual2 for detailed diagnosis and testing procedures.
Knock Sensor (KS) Diesel Engine (EEC-V)
Gasoline Engines WARNING: RED-STRIPED WIRES CARRY 115V
DC. SEVERE ELECTRICAL SHOCK MAY BE
During engine operation the knock sensor RECEIVED. DO NOT PIERCE.
(KS)( 12A699) will generate a signal to the powertrain
control module (PCMX 12A650) to retard timing if the CAUTION: Do not pierce engine electrical wires
engine knocks. or damage to the harness may occur.
KNOCK SENSOR Manual. 2
12A699
A20798-A

ALL RIGHTS RESERVED
Safeguards 5. To install, reverse removal procedure. lighten

PCM retainer screw to 3-4 N·m (27-35 Ib-in).
lighten engine control sensor wiring connector
retainer bolt to 4 N·m (35 Ib-in).
control module (PCMX 12A650) relearns its
NUT AND WASHER ASSEMBLY
Always disconnect the battery cable prior to N621905-S2
service or replacement of EEC-IV or EEC-V TIGHTEN TO
4-5.6 N·m
systems electronic engine controls. (35-50 LB-IN)
2. Follow Diagnostic Procedures as outlined in the
Powertrain Control/Emissions Diagnosis
Manual. 3
3. Disconnect electronic engine controls from wire
harness before measuring for continuity,
resistance or energizing with a B+ source.
4. Never measure voltage or resistance directly at
the powertrain control module.
BRACKET
ASSEMBLY
12A692
Powertrain Control Module (PCM)

Gasoline and Diesel Engines
Removal POWERTRAIN
1. NOTE: Refer to EVTM for location of PCM in CONTROL
MODULE
specific vehicle. 12A650
Disconnect negative battery cable.
2. Loosen engine control sensor wiring (12A581) to A24041·A
PCM connector retainer bolt.
3. Remove engine control sensor wiring connector
from powertrain control module (PCMX 12A650).
4. Remove the two PCM seal nuts and loosen left Throttle Position (TP) Sensor·
fender liner screws and remove liner or bend
down to clear powertrain control module. Remove Removal
powertrain control module. 1. Disconnect negative battery cable.


ALL RIGHTS RESERVED
2. Disconnect throttle position sensor (TP 2. NOTE: When throttle position sensor is installed
sensor)(9B989) from wiring harness. on the throttle body (9E926), the connector will
point toward the throttle body inlet on 4.9l and
7.Slonly.
Secure throttle position sensor to throttle body
THROTILE with two retaining screws. Tighten to 2-3 N·m
BODY-9E926 (18-27 Ib-in) on 4.9l engines. On 5.0/ S.8l,
tighten to 1.2-1.8 N·m (10.6-161b-in).
3. Connect electrical connector to harness.
4. Reconnect negative battery cable.
THROTTLE Accelerator Pedal (AP) Position Sensor

POSITION
SENSOR Diesel Engine
98989 The accelerator pedal (AP) position sensor is not
4.9L (SHOWN)
serviced separately. Replace accelerator pedal and
shaft assembly if AP position sensor requires service.
DIESEL ENGINES
ACCELERATOR PEDAL (AP)

POSITION SENSOR
(PART OF 9725)
ACCELERATOR PEDAL
POSITION SENSOR
SCREWS
(PART OF 9725)
ACCELERATOR
PEDAL AND SHAFT
ASSEMBLY-9725
7.3L (SHOWN)
V10028-A
3. If reusing TP sensor scribe alignment marks to

position when reinstalling. A22291·A
4. Remove two retaining screws.
5. Remove throttle position sensor.
Installation
1. CAUTION: Slide rotary tangs into position
over throttle shaft blade, then rotate throttle
position sensor CLOCKWISE ONLY to
Installed position. Failure to Install the
throttle position sen80r in this manner may
result In excessive Idle speeds on 5.0L and
5.8L.
Position the throttle position sensor so that the
connector points opposite the idle air control
valve (lAC valve)(9F715).

ALL RIGHTS RESERVED
Idle Validation Switch (IVS) Injector Driver Module (10M)

The idle validation switch (IVS) is not serviced Removal
separately. Replace accelerator pedal and shaft if idle
1. WARNING: RED-STRIPED WIRES CARRY
validation switch requires service. Refer to Section
115V DC. SEVERE ELECTRICAL SHOCK MAY
10-02.
BE RECEIVED. DO NOT PIERCE.
CAUTION: Do not pierce engine electrical
wires or damage to the harness may occur.
Disconnect battery ground cable.
2. Remove module bolts.
3. Loosen wiring connector retainer bolt.
ACCELERATOR PEDAL
IDLE AND SHAFT ASSEMBLY 4. Remove injector driver module.
VALIDATION 9725
SWITCH Installation
PART OF
9725 1. To install, reverse removal procedure. lighten
IDM retainer bolt to 3-4 N·m (27-35 Ib-in).
Intake Air Temperature (IAT) Sensor

Gasoline Engines
1. Disconnect negative battery cable.
2. Disconnect wire harness from intake air
A22292·A temperature sensor (IAT sensor)(12A697).
3. Remove intake air temperature sensor from
intake manifold (9424) (MFI engines) or from air
cleaner /tube (SFI engines).
Mass Airflow (MAF) Sensor 4. To install, reverse removal procedure. lighten
intake air temperature sensor to 16-24 N·m
Gasoline Engines (12-18 Ib-ft) on MFI engines (SFI is a plastic
The mass air flow sensor (MAF sensor)( 128579) is twist-lock part and this torque may be
located between the engine air cleaner (ACL)(9600) excessive).
and the throttle body (9E926).
The MAF sensor electronics module element and
housing are calibrated as a unit and must be serviced
as a complete unit.
CAUTION: Sensing elements located In the mass
airflow sensor should not be probed or cleaned.

ALL RIGHTS RESERVED
Intake Air Temperature (IAT) Sensor - Gasoline Engines
MFI ENGINE
5.0L AND 5.8L 7.5L
~-
® ~'."
/l~'
SFI ENGINE 4.9L A24042·A
Part Part
1 9K461 Intake Manifold 3 9600 SFI ACT Sensor
2 12A697 Intake Air Temperature 4 12A581 Wiring Harness
Sensor
(Continued)

ALL RIGHTS RESERVED
2. Disconnect wire harness from intake air

temperature sensor (IAT sensor).
3. Remove intake air temperature sensor from air
cleaner housing.
4. To install, reverse removal procedure. lighten
intake air temperature sensor to 16-24 N·m
(12-18 Ib-tt).
INTAKE AIR
TEMPERATURE (IAT)
SENSOR
12A697
5.8L 49 STATE
12A697
ACT SENSOR
VIEW~
11.0 HEX ~
_:- . A22293-A
Idle Air Control (lAC) Valve

5.0L MASS AIRFLOW Gasoline Engines
AND
5.8L CALIFORNIA ONLY A24055-A Removal
2. Disconnect the idle air control valve assembly
connector from the wiring harness.
Intake Air Temperature (IAT) Sensor 3. Remove the two idle air control valve retaining
Diesel Engine bolts.


ALL RIGHTS RESERVED
Idle Air Control (lAC) Valve - Gasoline Engines
BOLTS
(2 REQ'O)
IDLE AIR CONTROL VALVE GASKET

9F715 9F670
4.9~5.OL5." 7.5L
IDLE AIR CONTROL VALVE

9F715
5.IL UGHTrMG A207I8-A
4. Remove the idle air control valve (lAC 2. Install gasket and idle air control valve on throttle
valve)(9F715) and gasket. body or intake manifold surfaces.
IDLE AIR
CONTROL VALVE
9F715
V4801·D
Installation
3. Install retaining screws. Tighten to 8-11 N·m
1. NOTE: If scraping is necessary, be careful not to (71-971b-in).
damage sealing areas of idle air control valve or
throttle body gasket surfaces, or drop material 4. Connect electrical connector for the idle air
into throttle body, or intake manifold. control valve.
Make sure that both throttle body and idle air
control valve gasket surfaces are clean.

ALL RIGHTS RESERVED
5. Reconnect negative battery cable. 2. Disconnect negative battery cable.

3. Disconnect engine control sensor wiring from
engine coolant temperature sensor (ECT
sensor)(12A648).
4. Remove engine coolant temperature sensor from
intake manifold (9424).
engine coolant temperature sensor to 13-20 N·m
(10-15Ib-ft). Refill cooling system as outlined in
Section 03-03.
BOLTS
(2 REO' D)
V5853-C
Engine Coolant Temperature (ECT) Sensor

Gasoline Engines
1. Partially drain cooling system as outlined in
Section 03-03.

ALL RIGHTS RESERVED
Engine Coolant Temperature (ECT) Sensor - Gasoline Engines

COOLANT TEMPERATURE
FRONT OF ENGINE SENSOR
12A648 CCX>LANT
~ TORQUE TO TEMPERATURE
r-
13-20 N-m SENSOR
(10-15 LB-FT) 12A648
TORQUE TO
13-20 N-m
, (10-15 LB-FT)
CCX>LANT
TEMPERATURE
SENSOR
12A648
TORQUE TO
13-20N·m
(10-15 LB..FT)
..
FRONT OF ENGINE
4.9L
Engine Oil Temperature (EOT) Sensor

Diesel Engine
Removal
1. Disconnect engine oil temperature sensor
electrical connector.
2. NOTE: Approximately one quart of engine oil
must be removed prior to sensor removal.
Remove one quart of engine oil from high
pressure oil pump reservoir using Rotunda
Vacuum Pump 021-00037 or equivalent.
3. Remove engine oil temperature sensor.
Installation
1. Install engine oil temperature sensor.
2". Connect engine oil temperature sensor electrical
connector.
3. Fill engine oil to proper level.

ALL RIGHTS RESERVED
4. Refill oil pump reservoir with engine oil. Manifold Absolute Pressure (MAP) Sensor
Diesel Engine
1. Disconnect battery ground cable.
2. Disconnect vacuum hose from manifold absolute
pressure sensor (MAP sensor)(9F479).
3. Remove fasteners attaching manifold absolute
pressure sensor and bracket assembly below
cowl drip rail.
MANIFOLD
ABSOLUTE
PRESSURE
(MAP) SENSOR
: - - - - - - - . . - - - - - - 9F479
ENGINE OIL
TEMPERATURE
(EOT) SENSOR
Manifold Absolute Pressure (MAP) Sensor

(MFI Gasoline Engines Only) MAP SENSOR
VACUUM HOSE A22294-A
2. Disconnect vacuum source from manifold
absolute pressure sensor (MAP sensorX9F479). Barometric Pressure (BARO) Sensor
3. Remove fasteners attaching manifold absolute Diesel Engine
pressure sensor and bracket assembly below
cowl drip rail. Removal
4. Remove MAP sensor fasteners on Ale 1. Disconnect barometric pressure sensor electrical
evaporator case. connector.
5. To install, reverse removal procedure. 2. Remove barometric pressure sensor (BARO
sensor)( 12A644).
Installation
MANIFOLD ABSOLUTE
PRESSURE SENSOR 1. Install barometric pressure sensor.
A21336-B

ALL RIGHTS RESERVED
~ 2. Connect sensor electrical connector.
A22071-A
Installation
1. InstalllCP sensor.
2. Connect sensor electrical connector.
Injection Control Pressure Regulator

Diesel Engine
Removal
1. Disconnect injection control pressure regulator
A23336-B electrical connector.
2. Remove solenoid retaining nut and remove
solenoid.
Injection Control Pressure (ICP) Sensor 3. Remove injection control pressure regulator.
Diesel Engine
HIGH PRESSURE
Removal OIL PUMP
1. Disconnect injection control pressure sensor
2. Remove injection control pressure sensor.
FUEL
PRESSURE
REGULATOR
V957D-B

ALL RIGHTS RESERVED
Installation
1. Install injection control pressure regulator. Tighten
to 47 N-m (35Ib-ft).
2. Install solenoid and solenoid retaining nut. Tighten
to 6 N-m (53Ib-in).
3. Connect regulator electrical connector.
Heated Oxygen Sensor (H02S)

Gasoline Engines

Oxygen Sensor Wrench T94P-9472-A

2. Disconnect (H02S) electrical connector.
3. Remove the heated oxygen sensor FRONT OF
(H02S)(9F472) from the exhaust pipe using ENGINE
Oxygen Sensor Wrench T94P-9472-A. 3
~
4. To install, reverse removal procedure. Tighten A24056-A
heated oxygen sensor to 36-46 N-m (27-34Ib-ft).
Part
Heated Oxygen Sensor (H02S) - Gasoline Engines
HEATED OXYGEN SENSOR (H02S) 1 9430 Exhaust Manifold (Rear)
(F-250, F-350) 2 - Remove and Discard Prior to
9F472 HEATED OXYGEN
Sensor Installation
SENSOR (H02S)
(F-SUPER DUTY) 3 9F472 heated oxygen sensor
9F472 4 9430 exhaust manifold (Front)
HEATED
OXYGEN
SENSOR
9F472
FRONT OF
VEHICLE
FRONT OF VEHICLE ~ A24057-A
~ A24043-A

ALL RIGHTS RESERVED
Installation
1. Install exhaust back pressure sensor.
2. Connect sensor electrical connector.
OVER 8500 GVW

Exhaust Back Pressure Regulator (EPR)
Diesel Engine
Refer to Section 03-04F.
/
~
FRONT OF TURBOCHARGER
ENGINE
HEATED
OXYGEN
SENSOR
9F472
~
FRONT OF UNDER 8500 GVW
ENGINE
5.8L A24058-A
PEDESTAL ASSEMBLY
A22297-B
Exhaust Back Pressure (EBP) Sensor
Diesel Engine
Removal Camshaft Position (CMP) Sensor
1. Disconnect exhaust back pressure sensor
electrical connector. Diesel Engine
2. Remove exhaust back pressure sensor. Removal
1. Disconnect camshaft position sensor electrical
connector.
EXHAUST BACK 2. Remove bolt and camshaft position sensor.
PRESSURE SENSOR
A22296-A
A22295-A Installation
1. Install CMP sensor and bolt.

ALL RIGHTS RESERVED
2. Connect CMP sensor electrical connector. Vehicle Speed Sensor (VSS)

Diesel Engine
Removal
Knock Sensor (KS) 1. Disconnect battery ground cable.
Gasoline Engines 2. Disconnect vehicle speed sensor (VSS)(9E731)
3. Remove vehicle speed sensor.
1. NOTE: 7.5L and 5.8L have no knock sensor.
Disconnect knock sensor electrical connector. Installation
2. Remove knock sensor (KS)( 12A699) from 1. Install vehicle speed sensor.
cylinder block. 2. Connect sensor electrical connector.
3. To install, reverse removal procedure. Tighten 3. Connect battery ground cable.
knock sensor to 20-27 N·m (15-20 Ib-ft).
VEHICLE
SPEED
FRONT OF
I~""""""-"'-_ _ KNOCK SENSOR SENSOR
12A699
ENGINE
CYLINDER
BLOCK
6010
S.OL
A23696-A

ALL RIGHTS RESERVED
Idle Air Control Valve 2. CAUTION: Do not exceed three minutes soak
time, and do not use choke cleaner; an
Gasoline Engines internal O-ring may begin to deteriorate.
Recommended Cleaning Procedure Soak the mechanical portion in Carburetor
1. NOTE: Applies only to 5.8l lightening and 7.0l. Tune-Up Cleaner D9AZ-19579-BA meeting Ford
specification ESR-M 14P9-A or equivalent for
CAUTION: Use only specified cleaner. Do not three minutes maximum.
spray directly on throttle plate or use any
type of scrubbing method. 3. With the mechanical portion completely
submerged, shake in all directions: up, down,
Make sure bypass actuator is operating properly. right, and left. Then push in on the rod that mates
Refer to Powertrain Control/Emissions Diagnosis with the solenoid assembly, and again shake in all
4
Manual. directions with the unit submerged and the rod
2. Remove air cleaner outlet tube (9B659). held in as far as possible.
3. Disconnect idle air control valve connector. 4. Remove the unit from the cleaner and dry out
4. Connect Rotunda Air Bypass Valve Actuator thoroughly using compressed air.
113-00009 and Fuel Injector Tester / Cleaner
5. Start the actuator and then start the vehicles that
ADJUSTMENTS
do not have air flow meters. Do not start
engines (6007) of vehicles equipped with mass Throttle Position (TP) Sensor
air flow sensor (MAF sensor)( 12B579).
Gasoline Engines
6. Spray Carburetor Tune Up Cleaner
D9AZ-19579-AA meeting Ford specification The throttle position sensor (TP sensor)(9B989)
ESR-M 14P9-A or equivalent into idle air control cannot be adjusted. The throttle position sensor must
valve port for five seconds while actuator is be replaced if servicing is required.
operating. Avoid direct spraying on throttle plate
bore area.
7. Turn off the actuator and stop engine, (if running).
Allow solvent to soak for 15 minutes. Accelerator Pedal (AP) Position Sensor
8. Turn on actuator and start engine. Do not start Diesel Engine
engines on vehicles equipped with a mass air flow The accelerator pedal (AP) position sensor cannot be
sensor. adjusted. If service is required, replace accelerator
9. On vehicles with mass air flow sensors, spray pedal and shaft.
carburetor cleaner into idle air bypass passage
for no longer than six seconds. On all other
vehicles, spray for up to one minute. SPECIFICATIONS
10. Operate the actuator and make sure the solvent
is purged from the idle air control valve (lAC TORQUE SPECIFICATIONS
valve)(9F715).
Description N·m Lb-Ft
11. Turn off actuator and stop engine, (if running).
Idle Air Control Valve to Throttle 9.5 7
12. Install air cleaner outlet tube. Start actuator and Body
engine and run engine for one minute to dry out Throttle Position Sensor to 2.4-3.8 21-34
solvent residue. Throttle Body 4.9L/7.5 (Lb-In)
13. Disconnect actuator from bypass valve. Connect Throttle Position Sensor to 1.2-1.8 11-16
idle air control valve electrical connector. Throttle Body 5.0L /5.8L
14. Start engine and check for normal operation. PCM Support Bracket Screw 2.7-3.7 24-32
(Lb-In)
Alternate Cleaning Procedure
MAF Sensor-to-Bracket 4.7-5.0 42-46
1. NOTE: Method to be used only when Rotunda Air (Lb-In)
Bypass Valve Actuator 113-00009 and Fuel Engine Air Cleaner Tube Clamps 1.4-2.5 15-22
Injector Tester /Cleaner 113-00001 or equivalent (Lb-In)
for the recommended method are not available.
IAT Sensor 8-13 6-8
Remove the idle air control valve from the upper
ECT Sensor 13-20 10-15
manifold assembly as outlined. Remove the
electrical solenoid assembly from the mechanical H02S-to-Converter 36-46 26-34
portion of the idle air control valve by removing Engine Control Sensor Wiring 3.7 32
the two screws, then sliding the mechanical Connector-to-PCM (Lb-In)
portion away from the solenoid. (Continued)


ALL RIGHTS RESERVED
TORQUE SPECIFICATIONS (Cont'd) ROTUNDA EQUIPMENT

Description N·m Lb·Ft Model Description
MAP Sensor-to-Bracket 4.7-5.0 42-46 113-00001 Fuel Injector Tester / Cleaner
(Lb-In)
113-00009 Air Bypass Valve Actuator
Wiring Connector to IDM 3.7 32
021-00037 Vacuum Tester
(Lb-In)

Tool Number /
T94P-9472-A
Oxygen Sensor Wrench

ALL RIGHTS RESERVED
05-00-1
GROUP
DRIVELINE
AXLE AND DRIVESHAFT, SERVICE •....•••..•••.......•.•..••.. 05-00~1 DIFFERENTIAL, TRACTION-LOK@ LIMITED SLIP,
AXLE, 10.2S-INCH RING GEAR ...•....•.......•.•..••••...•....OS-02A-1 8.8-INCH RING GEAR...•.......•..........•.....................OS-02H-1
AXLE, FRONT DRIVE, DANA MODEL 60 DRIVESHAFT..•..•................•........................•...•.........05-01-1
MONOBEAM ......•.•.••......••..••••.....•..•..•....•.............OS-03B-1 WHEEL HUBS AND BEARINGS, FULL-FLOATING
AXLE, FRONT DRIVE, DANA MODELS 44 AND AXLE ............••....••...•..............•.....••....•................OS-02B-1
50 OS-03A-1 WHEEL HUBS AND BEARINGS, FRONT WHEELS,
AXLE, INTEGRAL CARRI.ER, 8.8-INCH RING 4-WHEEL DRiVE.......•................................•..........OS-03C-1
GEAR .•••..•.••..•.........•••..•••••..••......•.....•.•..••.•.•.......OS-02G-1 WHEEL HUBS AND BEARINGS REAR, DANA
AXLE, REAR, DANA .....••.•..•••••...•....•...........•.•...•......05-02D-1 FULL-FLOATING AXLE .......••...•.....•.•.•.•...•....•.......OS-02E-1
DIFFERENTIAL, DANA LIMITED SLIP .•.•...•••....••...•••..OS-02F-1
DIFFERENTIAL, LIMITED SLIP, 10.2S-INCH RING
GEAR •••••••.••.••..•.......••••..••.•.......•............•••.•.••.....OS-02C-1
SECTION 05·00 Axle and Driveshaft, Service

VEHICLE APPLICATION •........•..•••.•.•.••....•.•.••••.••.•....•.05-00-1 DIAGNOSIS AND TESTING (Cont'd.)
DESCRIPTION AND OPERATION Preliminary Diagnosis•.•...•••..•........•.•..•.••........•..•OS-O0-7
Axle Identification Tag .••...•...•••.•••.........•••.....•.•..•...05-00-2 Symptom Charts .......•....•...••...•...........•................05-00-17
Braking System,Anti-lock, Rear and CLEANING AND INSPECTION
4-Wheel.•.•..••...••..•.•...••••.•......•.•..••..••.•....•....•......05-00-5 Inspection After Disassembly of the Axle .....•...•...05-00-27
Driveshaft, Front .••.•••......••...••.•.•.•.•..•...•.•...•..••......05-00-3 Inspection. Before Disassembly of Axle .•...•..........05-00-26
Driveshaft, Rear •••..•.•..•.....•..•..•••.•.•.....••.•••...•......••.05-00-3 ADJUSTMENTS
Driving Axle, Front .....•..•••..••.......•.•••...•...........•••.•.•05-00-5 Axles •.......•....•............••.....•...•.....•..•....................05-00-28
Driving Axle, Rear ..:..•.••.••.•••........•.••••.•.•......•.••••.•••05-00-5 Coupling Shaft Angle Adjustment .................•.......OS-00-28
Front Axle Identification Tag .•...•..•......•.•.••.••..•....•..05-00-2 Driveline Angle Correction ..•...•.......•.....••.............05-00-28
DIAGNOSIS AND TESTING Driveshaft and Pinion Angle Adjustment OS-00-28
Component Tests ....•...••••.••.••..•.••'••.••...••.........•....05-00-19 Driveshaft Runout and Balance •..••••....•........••.•..••05-00-28
Driveline Vibration •.•.•..••••........•...................•••..05-00-19 Pinion and Ring Gear Adjustment ..••.....................05-00-31
Traction-Lok@ Differential .•••....•••..•.•...•....•...•..•.05-00-22 Slip-Yoke Spline ......••.............................•..•...•.•...05-00-32
Universal Joint Flange Runout Check, Rear LUBRICATION
Axle •.•••....••...••.•••.•....•..........••...•.•..•.........•...•05-00-22 Axle Lubrication, Rear..•....•.•....•.•..•..........•...........05-00-32
Inspection and Verification ..•.•••.•.•.....•....•......•...••..05-00-5 Draining and Filling ...•.........•............................•...05-00-33
Analysis of Inoperative Conditions .•..........•.•....05-00-16 SPECIFICATIONS .......•.•...•.....••.•..•...........•.....•..•.•...05-00-33
Analysis of Leakage .•••••.........•..•.......•..••..........05-00-10 SPECIAL SERVICE TOOLS/EQUIPMENT .........•........05-00-40
Analysis of Vibration.•.••.••......•....••.....••.............OS-oO-11
VEHICLE APPLICATION
F-150, F-250, F-350 4x2 and 4x4, F-Super Duty and
Bronco
1995 F-150, F-250, F-350, Bronco, F-Super D~ty Powertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
05-00-2 Axle and Driveshaft, Service 05-00-2
Axle Identification Tag Ford Axle Identification Tag

/ S = STERLING PLANT
Location of the axle identification code on the rating
PLANT CODE
plate is shown in the illustrations. The first two digits of
the axle code (located in the right lower corner of the
o
S832F
plate) are rear axle identifiers. The third digit identifies
a front axle. Refer to Section 00-01 for a complete MONTH
listing of the codes. YEAR DAY I
3.55 10.25 rmrAf2ll
DATE: 2/91 GVWR: 6600 LB/2994 KG
AXLE RING GEAR
FRONT GAWR: 3320 LB REAR GAWR: 4004 LB RATIO DIAMETER E6469-E
1506KG WITH 1816KG WITH
The plant code for an axle denotes a particular design
LT 215/85R 160 TIRES LT 215/85R 160 TIRES
and specific ratio, and if it is a conventional or limited
16 x 6K RIMS 16 x 6K RIMS
slip type. In addition, the plant code will not change as
AT 51 PSI COLD AT 58 PSI COLD
THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE
long as that particular axle assembly never undergoes
SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE an external design change. If, however, an internal
.
VIN:
TYPE.
~T'~
1FTBF25HSMLAOOOOO
(a) (b)
(c) (d) (e) (f) (g) (h)
FOO83
T0112
design change takes place during the production life of
the axle and that internal change affects service parts
interchangeability, a dash and numerical suffix will be
added to the plant code.
II~IIIIIIIIIIIIIIIIII Note that plant codes are identical except the tag
below shows a numeric. This means that AS AN
ASSEMBLY both axles are interchangeable; however,
I
48
internally they are different. Therefore, each would
require different internal service parts at service time.
we SPRING INTERCHANGEABILITY
133 2 029 AFFECTED
(a)(b)(c)(d) INTERNALLY
CE4147.J
Rear axles (4001) have a metal tag secured under

adjacent axle housing cover bolt heads listing Ford
and Dana part numbers and the ratio. Front drive axles
have a similar tag.
The plant code on the axle identification tag is to be
o 3.55 10.25
MONTH
YEAR I
DAY
r!lrAf2ll
used as the official service identifier. RATIO-CONVENTIONAL RING GEAR
AXLE SHOWN DIAMETER
Dana Axle Identification Tag (LIMITED SLIP = 3L55) E6470-E
RATIO CUST. AXLE ASSEMBLY NO.

PREFIX LETTERS
000 OOOCRIIO.....t - - - I - - - r - SUFFIX LElTERS
DANA AXLES
INCLUDE ON UMITED SUP

ASSEMBLIES ONLY
(lNSTAu.ED UNDER 2 O'a..OCK AND 4 O'CI.OQ( BOLTS ON AXLE HOUSING COVER)
Front Axle Identification Tag

The front axle identification tag is a bar code label on
the rear facing surface of the axle support arm,
passenger side.

ALL RIGHTS RESERVED
Driveshaft, Front NOTE: Whenever the vehicle is raised on a hoist,

The front driveshaft connects the power flow from the inspect the universal joint slip yoke boot for rips or
transfer case to the front drive axle. It incorporates tears. Replace if required.
two single Cardan universal joints, a driveshaft with a CAUTION: Under no circumstances is the
splined stub shaft end, a universal joint slip yoke boot driveshaft (4602) to be clamped in the jaws of a
(4421) with two clamps (one large and one small), and vise or similar holding fixture. Denting or
a driveshaft slip yoke (4841) which attaches to the localized fracture of the tube may result which
transfer case. F-350 4x4 vehicles incorporate a could cause driveshaft failure during vehicle
double Cardan universal joint in the front driveshaft. operation.
Driveshaft, Rear Some vehicles use a one-piece steel or aluminum

The driveshaft (4602) or coupling shaft is composed slip-yoke type driveshaft. A universal joint and splined
of the universal joints, connecting shafts, attaching driveshaft slip yoke (4841) are located at the
flanges, and slip-yokes. The number of shafts and transmission end of the shaft, where they are held in
universal joints used depends on the vehicle alignment by a bushing in the extension housing
application. (7A039). The splined driveshaft slip yoke and
transmission output shaft allow fore and aft movement
of the driveshaft as the rear axle (4001) moves up and
down. This provides smooth performance during
vehicle operation. An oil seal at the transmission
(7003) prevents leakage and protects the driveshaft
slip yoke from dust, dirt and other harmful material. A
rear universal joint attached by either two U-bolts or
two straps and four nuts are used where the driveshaft
mates with the rear axle companion flange at the rear
axle or a driveshaft rear flange on vehicles equipped
with circular rear axle companion flange.
Driveshaft Assemblies
(Jr~
F·150
Part Part
1 4A378 Drivesh aft Centerin g Socket 5 34806-S2 Lockwasher
Yoke 6 386867-S U-Bolts
2 4635 Universal Joint 7 - Snap Rings (Part of 4635)
3 4602 Driveshaft 8 - Bearing (Part of 4635)
4 382836-S100 Nut 9 - Seal (Part of 4635)

ALL RIGHTS RESERVED
Part Part
10 - Spider (Part of 4635) 12 375646-S2 Nut
11 4841 Driveshaft Slip Yoke 13 4851 Rear Axle Companion Flange
(Continued) 14 4859 Drive Pinion Oil Seal
Deflector
Slip Yoke Designs

Part
6 4841 Driveshaft Slip Yoke,
High Inertia
7 - Damper (Part of 4841)
Others use a coupling shaft in conjunction with a

driveshaft. Care must be taken to align the driveshafts
as shown in the figures. The two-piece driveline
system incorporates a ··necked down" coupling shaft
stub with a ··blindspline" feature which assures
PARTIAL OR
positive phasing action (except F-Super Duty
NON-COUNTERBORE SLIP-YOKE WITH Chassis).
SLIP YOKE COUNTERBOREIPILOT All two-piece driveline vehicles are equipped with
driveshaft center bearing supports (4800) that are
prelubricated and sealed for the bearing life.
All universal joints are of the lubed-for-life
needle-bearing type except F-Super Duty Stripped
Chassis which have lubrication fittings. Replacement
universal joints equipped with grease fittings should be
lubricated at the intervals specified in Section 00-03.
The universal joint bearings are retained on the spiders
by snap rings and U-bolts on some applications.
The driveshafts are balanced; therefore, if the vehicle
SLIP YOKE' is being undercoated, the driveshafts and all open
WITH DAMPER
spline areas must be covered to prevent undercoating
Enss-c material from getting on the driveshafts.
Two types of driveshaft connecting joints are available
Part on different vehicles:
• single Cardan universal joint
1 4841 Driveshaft Slip Yoke,
Non-Counterbore • double Cardan universal joint
2 - Counterbore / Pilot The Bronco rear driveshaft is of the double Cardan
(Part of 4841) type which incorporates two universal joints, a
3 4841 Driveshaft Slip Yoke, driveshaft centering socket yoke (4782), and a
Counterbore / Pilot driveshaft center yoke (4784) at the transfer case end
4 4841 Driveshaft Slip Yoke, of each shaft. A single universal joint is used at the
Low Inertia axle end of the driveshaft.
5 - Damper (Part of 4841)
(Continued)

ALL RIGHTS RESERVED
Rear Driveshaft and Coupling Shaft, Bronco
UNIVERSAL JOINT DRIVESHAFT SLlP-

SLIP-YOKE BOOT YOKE-4841
DOUBLE CARDAN 4421
UNIVERSAL JOINT (TO DRIVE AXLE)
(TO TRANSFER CASE)
E7158-B
Driving Axle, Front Braking System, Anti-lock, Rear and 4-Wheel

• F-150-250, Bronco 4x4: Dana Model 44 or 50 front F-Series (except F-Super Duty) vehicles use the Rear
axle Anti-lock Braking System (RABS). Bronco vehicles are
equipped with Four Wheel ABS, which incorporates
• F-350 4x4: Dana Model 60 monobeam front axle the same rear axle-mounted rear brake anti-lock
sensor as the RABS system. For a detailed
description of ABS, refer to Section 06-09B. Rear
axles (4001) in vehicles equipped with the RABS
Driving Axle, Rear contain a rear brake anti-lock sensor and anti-lock
Three rear axles (4001) available on F-Series and speed sensor ring mounted in the carrier. F-Super Duty
Bronco vehicles are: Vehicles incorporate the rear brake anti-lock sensor
and anti-lock speed sensor ring as a signal generator,
• F-Super Duty: Model Dana 80 11.25-inch rear axle not for a RABS system. The signal is used for the
speedometer system along with other vehicle systems
• F-250-350: Ford 10.25-inch ring gear rear axle that require a road speed signal. F-Super Duty
• F-150, Bronco: Ford 8.8-inch ring gear rear axle Stripped Chassis vehicles do not incorporate the rear
brake anti-lock sensor and anti-lock speed sensor
Driving Axle (Rear on 2WD and Front and Rear ring. For a detailed description of the RABS, refer to
on4WD) Section 06-09A. The system features an anti-lock
The axle drive pinion receives its power from the speed sensor ring that is pressed on the differential
engine (6007) through the transmission (7003) on case (4204) behind the ring gear and pinion. If the
2WD and through the transfer case on 4WD vehicles. anti-lock speed sensor ring is removed, it must be
The hypoid pinion gear rotates the differential case discarded an~ replaced with a new one. The anti-lock
(4204) through engagement with the ring gear, which speed sensor ring works in conjunction with a rear
is bolted to the case outer flange. Inside the differential brake anti-lock sensor. This rear brake anti-lock
case, two differential pinion gears are mounted on the sensor is retained in a bore at the top of the carrier
differential pinion shaft (4211) which is pinned with a housing and fastened by one bolt. There is a space
lock bolt to the differential case. These pinion gears provided between the ring gear and pinion and
are engaged with the side gears to which the axle anti-lock speed sensor ring for measuring the ring gear
shafts (4234) are splined. Therefore, as the and pinion backface runout. For anti-lock speed
differential case turns, it rotates the axle shafts and sensor ring removal and installation procedures refer
wheels. When it is necessary for one wheel and axle to the appropriate rear axle section.
shaft to rotate faster than the other, the faster turning
side gear causes the differential pinions to roll on the
slower turning side gear to allow differential action DIAGNOSIS AND TESTING
between the two axle shafts.
Certain rear axle (4001) and driveline trouble
symptoms are also common to the engine (6007),
transmission (7003), rear wheel bearings (1225),
tires, and other parts of the vehicle. For this reason,
be sure that the cause of the trouble is in the rear axle
before adjusting, repairing, or replacing any of its
parts. See Section 00-04.

ALL RIGHTS RESERVED
Certain trouble symptoms may be caused by limited

slip differentials. Check the vehicle certification and
axle ratio tag to determine the type of differential.
U-Joint Inspection
Prior to checking driveline angularity, inspect the
universal joints for proper operation.
Place the vehicle on a frame hoist and rotate the
driveshaft (4602) by hand. Check for rough operation
or seized universal joints. If the universal joint shows
signs of seizure, excessive wear or improper seating,
scribe alignment marks on the driveshaft and rear axle
companion flange. Remove the driveshaft and remove
and replace the universal joint. Install the driveshaft in
the marked original position.
Alignment Inspection, Rear Axle
E6007-B
1. Raise the vehicle on a hoist to allow the rear axle
to be freely suspended. 3. Adjust both wheels so that the markings face the
2. Using white chalk or paint, mark a small area at front of the vehicle. Using a tape measure,
the center of each rear tire and scribe a vertical measure the distance between scribe marks and
line on it. record this reading (front reading).
4. Rotate the rear wheels so the markings are

directly underneath the vehicle. Measure the
distance between the scribe marks and record
this reading (bottom reading).
Bottom Reading
MEASURE CHALK LINE

TO CHALK LINE
.,
FRONT Of
VEHICLE
MEASURE
HERE
E6009-2A

ALL RIGHTS RESERVED
05-00-7 Axle and Drlveshaft, Service 05-00-7
5. Rotate the rear wheels so the markings face the

rear of the vehicle. Again, measure and record
the distance between scribe marks (rear
reading).
Rear Reading
E601G-2A
6. The difference between the front and rear Noise Acceptability

readings is the toe-out or toe-in condition of the A gear-driven unit, especially an automotive drive axle,
axle housing (Steps 3 and 5). will produce a certain amount of noise. Some noise is
All numbers are for example only. acceptable and may be audible at certain speeds or
Front reading: 52-3/ 16 inch under various driving conditions such as a newly
Rear reading: 52-1/16 inch paved blacktop road. The slight noise is not
Toe-out: 2/ 16 inch or 1 /8 inch detrimental to operation of the rear axle and must be
Toe-in occurs when the front reading is less than considered normal.
the rear reading. With the Traction-Lok@ Limited Slip differential axle,
7. To determine camber, find the average of the slight chatter noise on slow turns after extended
front and rear readings (obtained in Steps 3 and highway driving is considered acceptable and has no
5). Then, subtract the bottom reading from this detrimental effect on the locking axle function.
(obtained in Step 4).
Preliminary Diagnosis
Average of front and rear readings:
52-2/ 16 inch Question the Customer
Bottom reading: 52-2/16 inch The preliminary diagnosis begins with the service
Difference or camber: 0 inch technician asking the customer enough diagnostic
Positive ( +) camber is when the bottom reading questions; especially for conditions of noisy operation
is less than the average of the front and rear and / or vibration.
readings. Negative (-) camber is when the bottom
reading is greater than the average of the front Always ask the customer about:
and rear readings. 1. The exact nature of the symptom. If it is a
vibration, how is it felt? If a noise, what kind? Is it
8. Results of the measurements taken must conform
high-pitched, a rumbling noise or some other
to the following specifications:
concern?
Tape measure specification:
Camber: 0 ± 5/32 inch 2. The driving conditions in which the symptoms
Toe-in: 0-1 / 16 inch appear: road speed, drive or coast, on turns or on
Toe-out: 0-3/ 16 inch a grade only.
If the axle housing does not meet this 3. Whether the condition is constant or variable.
specification, it must be replaced. Does a noise increase in pitch with speed or
9. If the axle housing is replaced, repeat Steps 2 some other factor?
through 7. All information should be written on the service order
so that the technician will know where to start looking.
The technician doing the diagnosis must be able to
identify the axle concern from what is written on the
order following the road test.
It is, of course, preferable to have the customer
demonstrate the symptoms in a road test whenever
possible.

ALL RIGHTS RESERVED
Road Test Conditions

Mode
A road test is mandatory for any customer concern of Controlled deceleration;
FLOAT
noise and / or vibration that is not eliminated by the backing the throttle
on-hoist check of chassis components. The Road Test continually to prevent either
Form is arranged to record the conditions that may be braking or accelerating torque
heard or felt during this test. from the engine.
The Road Test Form lists four operating conditions or
To perform a good diagnostic check it is important to
modes in which some axle noises come and go: Drive,
operate the vehicle in all four modes and check off
Cruise, Coast and Float.
those in which the noise occurs. The modes are
defined in the preceding chart. Write down the
Mode Conditions kilometers-per-hour (miles-per-hour) range at which
DRIVE Accelerating the vehicle; a
both noise and vibration occur. On vehicles equipped
definite throttle depression with overdrive transmissions, evaluate rear axle noise
applying engine torque. with the transmission in DIRECT DRIVE and not in
OVERDRIVE. Transmission noise can be mistaken for
CRUISE Maintaining a constant speed
with the throttle applied.
rear axle noise when in overdrive.
COAST Decelerating with the throttle
closed.
(Continued)

ALL RIGHTS RESERVED
Slip Yoke Designs
ROAD TEST FORM

1. Did condition exist when vehicle was new? DYes o No
How did condition begin?

0 Gradually occurred . Mileage
0 Suddenly occurred Mileage
2. Vehicle NVH between MPH and MPH
3. Neutral engine run-up NVH? D Yes o No
4. What driving conditions affect the NVH?
0 Float
0 Drive
0 Coast
0 Cruise
5. If a vibration, where is the vibration noticed?
0 Seat
0 Steering wheel
0 Instrument panel pad
0 Floor
0 Hood and fenders
6. If a noise, define as:
0 Buzz
0 Moan
0 Drone
0 Rumble
0 Hum
Describe: _
0 Other
E9708-A

ALL RIGHTS RESERVED
Analysis of Leakage
Most rear axle leakage conditions can be corrected
without a teardown. However, it is important to clean
up the leaking area enough to identify the exact
source.
A plugged rear axle housing vent (4022) can cause
excessive pinion seal lip wear due to internal pressure
buildup.
Make sure axle lubricant level is 6-14mm (1 / 4-9 / 16
inch) below bottom of fill hole.
Flange Yoke Seal
When the rear axle drive pinion seal (4676) leaks, it is
usually because it was not installed carefully or
properly, or because of poor quality on the seal journal
surface. 0.039 mm (0.05 INCH) OR GREATER
INDICATf=S EXCESSIVE WEAR
Any damage to the seal bore (dings, dents, gouges or
other imperfections) will distort the seal casing and
allow leakage past the outer edge of the rear axle
drive pinion seal.
The rear axle drive pinion seal can be torn, cut or
gouged if it is not assembled carefully. The spring that
holds the rear axle drive pinion seal against the rear
axle universal joint flange (4851) may be knocked out
and allow leakage past the lip.
E5517-E
The rubber lips can occasionally become hard (like
plastic) with cracks at the oil lip contact point. The Drive Pinion Nut
contact point on the rear axle universal joint flange is
usually black, indicating excessive heat. Marks, nicks, On some high-mileage units, there have been
gouges or rough surface texture on the seal journal of instances of oil leaking past the threads of the pinion
the rear axle universal joint flange will also cause nut. The condition can be corrected by removing the
leaks. Excessive rear axle drive pinion seal wear will nut and applying Pipe Sealant With Teflon@
be noted. The rear axle universal joint flange should be D8AZ-19554-A or equivalent meeting Ford
replaced if any of these conditions exist. specification WSK-M2G350-A2 on the threads and nut
face.
Metal chips or sand trapped at the sealing lip also may
cause oil leaks. This can cause a wear groove on the NOTE: Be sure to follow the correct procedure for
rear axle universal joint flange and heavy pinion seal setting the bearing preload when the nut is installed.
wear. Axle lubricant level should be 1 / 4-9 / 16 inch below
When any seal leaks, confirm that air passes freely bottom of fill plug hole. Make sure rear axle housing
through vent hose and fitting. Clean out as needed. vent is not plugged with dirt or debris.
Axle Shaft Seals
Axle shaft oil seals are susceptible to the same kinds
of damage as rear axle drive pinion seals if improperly
installed. The seal bore must be clean and the lip
handled carefully to avoid cutting or tearing it. Axle
shaft journal surface must be free of nicks, gouges and
rough surface texture.
Differential Seals
Refer to Section 05-02A.
Casting Porosity (Holes in Casting)
Occasionally there will be a rear axle housing (4010)
leak through small pockets in the metal. These
pockets (casting leakage) are caused by gas bubbles
in the casting process and are known technically as a
porous condition or porosity.
Because there is always the danger of changing the
axle's sound characteristics if torn down to replace
the carrier, service is preferable. There are two
recommended types of service:

ALL RIGHTS RESERVED
1. Peen in a small amount of body lead. Seal the Traction-Lok@ Differential

pocket with epoxy sealer that meets Ford WARNING: A VEHICLE EQUIPPED WITH A
Specification ESB-M3035-A. TRACTION-LOK@ DIFFERENTIAL WILL ALWAYS
2. In larger pockets, drill a shallow hole and tap it for HAVE BOTH WHEELS DRIVING. IF, WHILE THE
a small setscrew. Install the setscrew and seal it VEHICLE IS BEING SERVICED, ONLY ONE WHEEL
over with epoxy sealer that meets Ford IS RAISED OFF THE FLOOR AND THE REAR AXLE
Specification ESB-M3035-A. IS DRIVEN BY THE ENGINE, THE WHEEL ON THE
FLOOR COULD DRIVE THE VEHICLE OFF THE
Weld Leaks STAND OR JACK. BE SURE BOTH REAR WHEELS
Most minor weld leaks can be corrected with epoxy ARE OFF THE FLOOR.
sealer that meets Ford Specification ESB-M3035-A.
This includes the "puddle" or fill welds that join the Tires
axle shaft tube to the rear axle housing on integral WARNING: DO NOT BALANCE THE REAR WHEELS
axles. They sometimes leak and can be sealed easily. AND TIRES WHILE THEY ARE MOUNTED ON THE
If a weld is broken, the rear axle housing must be VEHICLE. POSSIBLE TIRE DISINTEGRATION
replaced. The alignment is too critical for field service. AND / OR DIFFERENTIAL FAILURE COULD
RESULT, CAUSING PERSONAL INJURY AND/OR
EXTENSIVE COMPONENT DAMAGE. USE
OFF-VEHICLE WHEEL AND TIRE BALANCER
ONLY.
CASTING
POROSITY Vibration is a definite concern with modern,
high-mileage tires if they are not "true" both radially
and laterally. They are more susceptible to vibration
around the limits of radial and lateral runout of the tire
and wheel assembly. They also require more accurate
balancing. Wheel and tire runout checks, truing and
balancing are normally done before axle inspection.
Sometimes a vibration concern can be corrected by
properly rotating or inflating the tires.
Driveline Angle
An incorrect driveline (pinion) angle can often be
detected by the driving condition when vibration
E3764-D occurs.
1. A vibration during coasting from 72 to 56 km / h
Analysis of Vibration (45 to 35 mph) is often caused by a high pinion
Few vibration conditions are caused by the rear axle. angle.
On a vibration concern, follow the diagnosis procedure 2. A vibration during acceleration, again around 56
in Section 00-04 unless there is a good reason to to 72 km / h (35 to 45 mph), may indicate a lower
suspect the axle. than specified pinion angle. Refer to Section
Most vibration in the rear end is caused by tires or 00-04 for pinion angle procedure.
driveline angle. When it is certain that the tires and driveline angle
are not the cause, inspect the axle. Refer to
Section 00-04.
U-Joint Wear
Prior to checking driveline angularity, inspect the
universal joints on the driveshaft for proper operation.
Place the vehicle on a frame hoist and rotate the
driveshaft by hand. Check for rough operation or
seized U-joints. If the U-joint shows signs of seizure,
excessive wear or improper seating, scribe alignment
marks on the driveshaft and rear axle companion
flange. Remove the driveshaft and remove and
replace the U-joint. Install the driveshaft in the marked
original position.
U-Jolnt Phasing
When assembling a slip between center driveshaft, the
universal joint yokes must be assembled to the
driveshaft on the same plane. If not, the assembly may
be out of balance, causing a driveline vibration.

ALL RIGHTS RESERVED
NOTE: Two-piece driveshafts cannot be assembled If the drive-away shudder cannot be serviced by
out of phase due to a master or "blind" spline located shimming down the driveshaft center bearing bracket,
on the yoke (except F-Super Duty Motorhome and proceed to the driveline angle checking and service
Commercial Chassis). procedure in the following paragraphs.
Axle Shaft Runout
Runout of the axle shaft (4234) at either end is an CENTER SUPPORT SHIM DIMENSIONS
infrequent, but possible, cause of rear end vibration. It
is advisable to check the axle shaft for runout of: . ~~---- 196.88mm (7 3/4 INCH)
1.
2.
the pilot (radial)
the flange face (lateral) ,.----- ....
~I.-_- 168.27mm (6518 INCH)-- I
3. the bolt circle (radial)

Refer to Section 00-04 for the checking procedures
and special service tool for axle shaft runout.
NOTE: If the axle shaft assembly is removed, check
runout of the shaft itself. The forged (unmachined) part 11.90 MM (15/32 INCH)
. DIAMETER-2 HOLES 6.35mm
of the shaft is allowed to have as much as 3.0mm
~l If-~!~~
(0. 120 inch) runout. This alone will not cause a
vibration condition.
Drive Pinion Stem and Rear Universal Joint
Flange
Rear axle universal joint flange runout should be
T
checked when all other checks have failed to show MATERIAL: HOT ROLLED LOW CARBON STEEL
the cause of vibration.
Y1978-E
Another cause of excessive rear axle universal joint
flange runout is improper installation of the rear axle Coupling Shaft Center Bearing Alignment
drive pinion seal. If the spring on the seal lip is
dislodged, it will jam up and cock the flange. Check Vehicle noise and vibration can be caused by
that possibility before replacing the differential ring dislocated and / or failed driveshaft center bearing
gear and pinion (4209) because of excessive rear axle support rubber insulator, contaminated driveshaft
universal joint flange runout. center bearing support (4800) or excessive
compression of the rubber insulator.
Two-Piece Driveshaft
The service for this condition is as follows:
The two-piece driveshaft used in longer wheelbase
light truck models introduces some special 1. Remove the coupling shaft from the vehicle.
considerations to diagnosis and testing. As compared 2. Perform the following steps:
with a one-piece installation, the two-piece design a. Remove the driveshaft center bearing
includes a front, or "coupling" shaft, a bracket and retainer.
rubber-insulated frame-mounted driveshaft center
bearing bracket, a splined slip joint and an b. Remove the rubber insulator.
intermediate universal joint at the front of the rear c. Press driveshaft center bearing support and
driveshaft. bearing retainer off the coupling shaft.
Bearing Shimming d. Press the dust slinger off the coupling shaft.
Drive-away shudder is the predominant symptom 3. Replace with Center Bearing Assembly Kit
associated with driveline angles condition on D9TZ-4800-A or equivalent in all cases except
F-15Q-250 vehicles with two-piece driveshafts. After E4TZ-4800-A for F-250 HD, F-350 and F-Super
eliminating coupling shaft phasing condition as the Duty Chassis Cab with the ZF transmission.
possible cause, driveline angles should be measured
4. First install driveshaft center bearing support in
and corrected. Drive-away shudder can usually be
rubber insulator and press bearing on shaft with
serviced by shimming down the driveshaft center
the turned-in lip toward the dust slinger (forward).
bearing bracket in 25mm (1 /4-inch) increments using
The support bracket must be installed with the
shims EOTZ-4A209-A or equivalent until the
deep flange rearward.
drive-away shudder is eliminated. Plate stock must be
used to maintain proper preload compression of the 5. Reassemble the coupling shaft.
rubber insulator. 6. Reinstall the driveline in the vehicle with the
Replace the existing bolts with the appropriate length yokes phased properly.
7/16-14 hex-head bolts. 7. Road test to verify resolution of condition.
Tighten bolts to 51-73 N·m (38-54Ib-ft).
Road test to verify resolution of condition.

ALL RIGHTS RESERVED
8. If vibration still exists, insert 1.59mm (1 / 16-inch)

shims between driveshaft center bearing bracket
and support plate (on bolt ends of driveshaft
center bearing bracket) to reduce compression of
the rubber insulator as required.
Axle Noise
Non-Axle Noise
There are a few other conditions that can sound just
like axle noise and have to be considered in diagnosis.
The three most common are exhaust, tires and trim
mouldings.
1. In certain conditions, the pitch of the exhaust may
sound very much like gear whine. At other times,
it can be mistaken for a wheel bearing rumble.
2. Tires - especially snow tires - can have a
high-pitched tread whine or roar similar to gear
noise. Radial tires, to some degree, have this
characteristic. Any non-standard tire with an SPALLED DAMAGED
unusual tread construction may also emit a roar ROLLER ROLLERS
or whine-type noise. E3760-E
3. Trim, grille and mouldings can also cause Rear wheel bearings are pressed into the axle housing
whistling or whining noises. tubes, making them more difficult to check. However,
Make sure that none of these are the cause of the the axle shaft is the inner race for the bearing. If the
noise before proceeding with an axle teardown and bearing is damaged, the roller surface on the axle
diagnosis. shaft may also be damaged. The rollers run
approximately on the center of the polished surface.
Analysis of Gear Noise
Gear Howl and Whine
Before disassembling the axle to diagnose and correct
gear noise, eliminate the tires, exhaust, trim items,
roof racks, axle shafts and rear wheel bearings as
possible causes.
The noises described under Road Test in this section
usually have specific causes that can be diagnosed by
observation as the unit is disassembled. The initial
clues are, of course, the type of noise heard on the
road test and the driving conditions.
Bearing malfunctions will normally be obvious at
disassembly. As noted earlier, differential pinion
bearings (4630) make a high-pitched, whistling noise,
usually at all speeds. However, if there is only one
differential pinion bearing that is malfunctioning, the
noise may vary in different driving phases.
Differential pinion bearings are frequently replaced
unnecessarily on axles with low mileage under 24, 139
km (15,000 miles) when!correcting gear noise. They
should not be replaced unless they are actually scored
or damaged, or there is a specific differential pinion E3761-D
bearing noise. Examine the large end of the rollers for
wear. If the differential pinion bearings original blend Chuckle
radius has worn to a sharp edge, the differential pinion Chuckle that occurs on the coast driving phase is
bearing should be replaced. usually caused by excessive clearance between the
Remember that the low-pitched rumble of a differential gear hub and the differential case bore. It
malfunctioning wheel bearing can also be caused by can also be caused by a damaged tooth on the coast
the exterior luggage rack or tires. side of the pinion or ring gear.
Rear wheel bearing noise might be mistaken for pinion Any damage to a gear tooth on the coast side can
bearing noise. Look at the rear wheel bearing carefully cause a noise identical to chuckle. Even a very small
before tearing down the axle. tooth nick or ridge on the edge of a tooth is enough to
cause the noise.
ALL RIGHTS RESERVED
You can often correct this condition and eliminate the 1. A gear tooth damaged on the drive side is a
noise simply by cleaning up the gear tooth nick or ridge common cause of the knock. This can usually be
with a small grinding wheel. If the cleaned up or corrected by grinding the damaged area.
damaged area is larger than 3.2mm (1 /8 inch), it is
advisable to replace the gearset. Damaged Teeth or Gearset
To check the differential ring gear and pinion, remove
as much lubricant as possible from the gears with
clean solvent. Wipe the gears dry or blow them dry
with compressed air. Look for scored or damaged
teeth. Also look for cracks or other damage.
If either gear is scored or damaged badly, the
differential ring gear and pinion must be replaced. If
there is metal broken loose, the rear axle housing must
also be cleaned to remove particles that could cause
damage later. Any other damaged parts in the rear
axle housing must be replaced.
Damaged Gear Teeth
E3756-E
Drive Side Knock
E3754·D
Scored Gear Teeth
E3757·E
2. Occasionally, the rear axle differential gear case

bolts (4216) will knock against the inside of the
rear axle housing casting. The cause may be too
little clearance due to casting flash or bumps. In
this case, the differential case (4204) can be
removed and the interference points ground out.
Another possibility is simply that one or more rear
axle differential gear case bolts are slightly
backed-out. Remove, replace and properly
Knock tighten the rear axle differential gear case bolts
Knock, which can occur on all driving phases, has using Stud and Bearing Mount EOAZ-19554-BA
several causes. In most cases, the technician will or equivalent meeting Ford specification
discover one of the following conditions: WSK-M2G349-A 1 on the threads.

ALL RIGHTS RESERVED
3. NOTE: Be sure to measure the end play with a

COMPANION
dial indicator and not by feel. Guessing is FLANGE HOLDING TOOL
inaccurate. TISP-4851-A
Knock is also characteristic of excessive end

play in the axle shafts. Up to 0.762mm (0.030
inch) is allowed in semi-float axles. The frequency
of knock will be less because the axle shaft
speed is slower than the driveshaft.
Clunk
Ford Rear Axles

Companion Flange Holding Tool T57T-4851-B 4. Lower the vehicle so that one rear wheel is
Companion Flange Holding Tool T78P-4851-A resting on a wheel chock to prevent it from
turning. The other rear wheel will then be used to
NOTE: Remove driveshaft when performing this measure total rear axle backlash.
procedure on circular rear axle companion flange
5. Rotate the free wheel slowly, by hand, until a feel
application.
of driving the rear axle is encountered. Position a
1. Raise vehicle on hoist. crayon or chalk firmly on the side of the tire
2. Use a rigid bar or pipe of suitable length and 305mm (12 inches) from the center of the wheel.
clamp one end to the rear axle companion flange Rotate the wheel slowly in the opposite direction
using Companion Flange Holding Tool until the feel of driving the rear axle is
T57T-4851-B for half-round rear axle companion encountered again.
flange on F-250-350 applications, and 6. Measure the length of the crayon or chalk mark
Companion Flange Holding Tool T78P-4851-A for on the tire. If the length of the mark is 25.4mm (1
F-150 (circular rear axle companion flange). inch) or less, the rear axle backlash is within
3. Clamp the other end to the frame or body allowable limits.
member in order to prevent movement of the rear 7. If the chalk mark is greater than 25.4mm (1 inch),
axle companion flange. check for these conditions:
a. Elongation of the differential pinion shaft
(4211) holes in the differential case.
b. Missing differential (4026), pinion, or
differential side gear thrust washer (4228).
c. Galling of the differential pinion shaft and
bore.
d. Excessive ring gear and pinion backlash.
Follow procedure for type of rear axl,e, to
check backlash.
Clunk, Dana Rear Axles
1. Apply parking brake to keep both rear wheels
from turning.
2. Mount a Dial Indicator / Magnetic Base
D78P-4201-B or equivalent on the differential
E4209-18 carrier housing with the indicator point positioned
to contact the pinion yoke 38. 1mm (1-1 /2 inch)
from the center line of the differential pinion shaft.
3. With the transmission in neutral and engine not
running, check the total rotational movement of
the pinion yoke. If the total reading on the dial
indicator is 1.9mm (0.075 inch) or less, the rear
axle backlash is within allowable limits.
4. Install new differential side gears and check the
backlash.
5. Install two new axle shafts.
6. Replace the differential case.
1995 F-150, F-250, F-350, Bronco, F-SuperDuty P~wertrain, Drivetrain July 1994
ALL RIGHTS RESERVED
7. Install the driveshaft so the index mark on the Analysis of Inoperative Conditions
driveshaft slip yoke (4841) is in-line with the If the axle fails to operate, there will be broken or
index mark on the driveshaft centering socket jammed-up parts. Analyze why the parts have broken
yoke (4782). This ensures original driveline to prevent the condition from recurring.
balance. If vibration exists after installation, refer
to Section 00-04. Broken Axle Shaft
8. lighten all rear axle universal joint flanges to Inspect a broken axle shaft for a twist in the spline next
123-149 N·m (91-110 Ib-ft). to the break.
Bearing Whine Breaks that occur away from the spline or that are not
accompanied by a twist in the spline may be caused
Bearing whine is a high-pitched sound similar to a by forging flaws and / or fatigue of the axle shaft.
whistle. It is usually caused by malfunctioning pinion
bearings, which are operating at driveshaft speed. Conditions that can cause a broken axle shaft include
Bearing noise occurs at all driving speeds. This forging flaws or excessive impact load to the axle
distinguishes it from gear whine which usually comes shaft as a result of a collision or other factors.
and goes as speed changes. Broken Pinion Stem
Chatter on Corners The drive pinion stem can break at any time if the
Chatter on corners is a condition where the whole rear differential pinion bearing preload is not set up
end vibrates only when the vehicle is moving. The properly. If there is no preload, the differential pinion
vibration is plainly felt and heard. In conventional bearing will turn relative to the axle shaft. This galls the
axles, extra differential thrust washers cause a roller shaft and generates heat which can draw the
condition of partial lockup that creates this chatter. temper away from the shaft.
Chatter noise on Traction-Lok@ axles can usually be Too much preload also generates bearing heat with
traced to erratic movement between adjacent clutch the same result. The break normally occurs between
plates and can be corrected with a lubricant change the two differential pinion bearings.
that includes friction modifier additive.
Broken Welds
Click at Engagement
Rear axle housing welds, if completely broken, call for
Click at engagement is a condition on axles of a slight replacement of the rear axle housing.
noise, distinct from a "clunk," that happens in
REVERSE or DRIVE engagement. It can be corrected Wheel Bearing Malfunctions
by installing a rear axle drive pinion shaft oil slinger Because of the severe loads they must handle, rear
(4670) between the rear axle universal joint flange and wheel bearings may require replacement at high
differential pinion bearing (4621). mileage. If a rear wheel bearing fails at low mileage, it
Axle Shaft Noise is often caused by overloading.
Axle shaft noise is similar to gear noise and Axle Lock-Up
differential pinion bearing whine. However, axle shaft Lock-up or seizure of the axle shaft usually indicates
bearing noise will normally distinguish itself from gear inadequate lubrication. The lubricant prevents friction
noise by occurring in all driving modes (drive, coast and helps cool the parts as they heat up. Without
and float), and will persist with transmission in enough lubricant, the heated parts get soft and may
NEUTRAL while vehicle is moving at problem speed. If eventually weld together. Check for lubricant leaks
the vehicle makes this noise, remove suspect axle after servicing.
shafts, replace rear wheel bearings and install a new
set of axle seals. Re-evaluate vehicle for noise before
removing any internal components.
Bearing Rumble
Bearing rumble sounds like marbles being tumbled.
This condition is usually caused by a malfunctioning
wheel bearing. The lower pitch is because the wheel
bearing turns at only about one-third of driveshaft
speed. Wheel bearing noise also may be high-pitched,
similar to gear noise, but will be evident in all four
driving modes.

ALL RIGHTS RESERVED
05·00·17 Axle and Driveshaft, Service 05·00·17
~ Symptom Charts
AXLE AND DRIVESHAFT SERVICE
Excessive rear axle noise. • N.V.H. problem. (Noise, vibration
and harshness.)
• Perform the N. V.H. tests to
determine whether the noise is a
N.V.H. caused by a rear axle
problem. Refer to Section 00-04.
• Worn or damaged rear wheel
bearing.
• Perform rear wheel bearing noise
test. Refer to Section 00-04.
Replace rear wheel bearings if
required.
• Rear axle differential. • Road test vehicle to ensure
problem is rear axle noise rather
than other system noise. Refer to
General Diagnostic Procedure.
Repair and replace parts as
requir~d.
Loud "clunk" in the driveline when • High idle speed. • Adjust idle speed.
shifting from reverse to forward. • Loose engine mounts. • Inspect, repair as reguired.
• Loose or worn driveshaft
components, rear axle companion
• Raise vehicle, rotate driveshaft by
hand to isolate problem as
flange attaching nut below specs. driveshaft or rear axle problem.
Repair or replace as required.
• Rear axle shafts or differential. • Remove and inspect. Repair as
necessary.
• Inoperative shock absorbers or
loose rear springs or suspension
• Inspect, repair or replace as
required.
arms.
• Excessive backlash in axle, or
transmission.
• Perform total backlash check of
rear axle. Repair or replace as
necessary.
• Insufficient lubrication. • Add lubricant as required.
Driveline "clunk" as vehicle starts to • Loose rear spring U-bolts. • Tighten U-bolts to specification.
move following a brake stop
(two-piece driveshaft).
• Worn or galled output driveshaft
and coupling shaft splines.
• Remove the driveshaft from the
vehicle. Clean the male splines
and inspect for worn or galled
splines. Replace if necessary.
• Worn or galled driveshaft slip yoke
splines.
• Clean and inspect the female
splines of the driveshaft slip yoke
for worn or galled condition.
Replace if necessary.
• Damaged driveshaft slip yoke
seal.
• Replace seal.
• Insufficient lubrication in driveshaft

slip yoke.
• Using a long handle (stencil type)
brush, apply long life lube evenly
on all the splines of the driveshaft
slip yoke. Reinstall driveshaft and
using a hand grease gun lubricate
the driveshaft slip yoke through
the zerk fitting with Premium
Long-Life Grease XG-1-C or -K or
equivalent meeting Ford
specification ESA-M1C75-B.
NOTE: Install the driveshaft slip
yoke making sure that the coupling
shaft and driveshaft are in phase.
On turns, the rear axle has a high

pitched chattering noise (Limited Slip
• Improper lubricant. Refer to
Maintenance Schedule in Section
• Road test vehicle - drive in tight
circles, 5 clockwise and 5
rear axles only). , 00-03 for complete information. counterclockwise. If chatter is still
evident, flush and refill - with
specified rear axle lubricant, and
dosage of friction modifier
additive. (See Lubricant
Specifications at the end of this
section.)
• Differential. • Remove differential, repair as
required.
1995 F-150, F-250, F-350, Bronco, F-Super Duty P~wertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
AXLE AND DRIVESHAFT SERVICE (Continued)

Ford Limited Slip does not work in
snow, mud or on ice.
• Differential. • Perform Limited Slip Differential
Operation Check in this section.
Repair as required per Section
05-02C.
Dana Limited Slip does not work in
snow, mud or ice.
• Worn or damaged differential. • Starting with one wheel on a
slippery surface, slightly apply the
parking brake. Gradually open
throttle. If the vehicle moves, the
rear axle is operating
satisfactorily. If no movement,
refer to Section 05-02F.
•
••
Driveline concerns. Rear spring U-bolt loose. Retighten U-bolt.
Universal joint worn or improperly
installed.
• Reinstall or replace universal joint.
• Coupling shaft driveshaft center

bearing bracket improperly
• Correctly install driveshaft center
bearing bracket and replace if
installed. damaged.
• Excessive runout in rear axle
companion flange or damaged
• Rotate rear axle companion flange
180 degrees and reinstall.
universal joint. Recheck and if not acceptable,
replace rear axle companion
flanges or rear axle shaft universal
joint and repair as required.
• Excessive lateral and radial tire
and wheel runout.
• Refer to Section 04-04.
• Excessive driveshaft runout. • Replace driveshaft or rotate

driveshaft 180 degrees and check
for out-ot-balance condition.
• Driveshaft out-of-balance. • Rebalance driveshatt.
• Driveline and pinion angles
out-of-specification.
• Adjust to specifications.
• Binding, damaged or galled splines

on driveshaft slip yoke.
• Check transmission for proper
lubricant, and clean and lap
splines. Lubricate splines with
Premium Long-Life Grease XG-1-C
or -K or equivalent meeting Ford
specification ESA-M 1C75-B.
Noise is the same on drive or coast. • Road noise. • Normal condition.
•
••
Tire noise. Rebalance or replace tire.
• Front wheel bearing noise. Adjust or replace wheel bearings.
• Improper driveline angles or
phasing.
• Adjust or correct as required.
Loud clunk in the driveline when

shifting trom reverse to forward.
• Loose or worn driveshaft
components, rear axle companion
• Inspect, repair, replace as
required.
flange attaching nut below
specifications.
Lubricant leaking from the pinion seal,
axle shaft oil seals or support arm to
• Dirt or other debris is bloc~ing
vent.
• Clean rear axle housing vent.
housing. • Observe end yoke dust shield for

damage in seal contact area or
• Replace end yoke and pinion seal
if damage is found.
dust slinger.
Noise tone lowers as vehicle speed is
lowered.
• Tire noise. • Rebalance or replace tire.
Similar noise is produced with vehicle • Engine noise. •• Refer to Section 03-00.
standing and driving. • Transmission noise. Refer to appropriate transmission
section.
Vibration. • Refer to Section 00-04. • Refer to Section 00-04.
Noise most pronounced on turns. • Differential side gears and pinion
gears.
• Replace gears.
Drive noise, coast noise or float noise. • Wheel bearings or differential side
bearings.
• Adjust or replace wheel or
differential side bearings.
• Ring gear and pinion. • Check ring gear and pinion. Adjust
or replace.

ALL RIGHTS RESERVED
05-00-19 Axle and Driveshaft, Service 05·00·19
Component Tests
Driveline Vibration
Driveline vibration exhibits a higher frequency and
lower amplitude than does high-speed shake. Driveline
vibration is directly related to the speed of the vehicle
and is usually noticed at speeds of 72 km / h (45 mph)
or higher. Driveline vibration can be perceived as a
tremor in the floor pan or is heard as a rumble, hum or
boom. Driveline vibration can exist in all drive modes,
but may exhibit different symptoms depending upon
whether the vehicle is accelerating, decelerating,
floating or coasting. If the vibration is particularly
noticeable during acceleration or deceleration,
especially at lower speeds, then driveline angle should
be checked. Driveline vibration can be duplicated by
supporting the axle upon a hoist or upon jack stands,
though the brakes may need to be applied lightly in
order to simulate road resistance.
1. Raise vehicle promptly after road-testing, on
twin-post hoist or jack stands, to prevent tire
flat-spotting. Engage drivetrain and run-up to
observed road test speed to verify presence of
vibration. If not evident, check non-driving wheels
with wheel-balancer spinner to rule out imbalance
as a possible cause. On 4x4's, unlock front hubs
or remove hub covers before spinning wheels. If F3931·H
required, balance non-driving wheels and repeat
road test. If vibration is still evident, proceed to
Step 3. Part
2. If vibration appeared in road-speed hoist test, Item Number Description
mark relative position of drive wheels on rear axle 1 4602 Driveshaft
(4001) or hub lugs to permit reinstallation in 2 4851 Rear Axle Universal Joint
original position, and remove wheels. Secure Flange (Circular)
brake drums, if present, by installing alilugnuts in 3 4782 Driveshaft Centering Socket
reversed position (on single-wheel vehicles) and Yoke
repeat road-speed run-up. Dual rear wheel 4 4851 Rear Axle Universal Joint
lugnuts may be installed in the normal orientation. Flange (Half-Round)
If vibration is gone, see drive wheel runout and A - Scribe Marks
balance procedures in Section 04-04. If vibration
persists, proceed to Step 3.
3. Inspect driveshaft (4602) for signs of physical
damage, missing balance weight, undercoating,
or improperly seated, worn, or binding universal
joints. Check the index marks (paint spots) on
rear of driveshaft and rear axle companion
flange. If these marks are more than 90 degrees
apart, disconnect driveshaft and reindex to align
marks as close as possible. Clean driveshaft and
replace universal joints as necessary, or replace
driveshaft if damaged. After any corrections are
made, recheck vibration at road test speed. If
gone, reinstall wheels and road test. If vibration
persists, proceed to Step 4.

ALL RIGHTS RESERVED
4. With vehicle on hoist and wheels off, measure 6. Excessive driveshaft runout may originate in the
runout at front, center, and rear of driveshaft with driveshaft itself or in the rear axle companion
indicator, rotating driveshaft by turning a brake flange. To determine which, compare the two
drum or rotor. On a one-piece driveshaft, if runout high points marked in Steps 4 and 5. If the marks
exceeds .89mm (.035 inch) at front or center, the are close together, within about 25mm or 1 inch,
driveshaft must be replaced. If front and center the shaft is eccentric, and should be replaced and
are within this limit, but rear runout is not, mark checked for vibration. If the marks are on
the rear runout high point and proceed to Step 5. opposite sides of the driveshaft, about 180
If runout is within limits at all points, proceed to degrees apart, the yoke or rear axle companion
Step 7 or driveshaft balancing procedure under flange is responsible. After replacing, check for
Adjustments. runout. When replacing a rear axle companion
flange, driveshaft runout should not exceed
.89mm (.035 inch). When runout is within limits,
recheck for vibration at road speed. If vibration
persists, balance the driveshaft.
CHECKING 'OsmON OF RUN-QUT MARKS
FIRST
RUNQUT
MARK
SECOND
RUNOUT
MARK
5. NOTE: Move universal joints in each direction of REPLACE DRIVESHAFT

rotation during reindexing. If a universal joint feels
stiff or has a gritty feel in any direction, replace
the universal joint.
Note or mark the indexing of driveshaft to rear FIRST SECOND
RUNOUT
axle companion flange. Disconnect the MARK
RUNOUT
MARK
driveshaft, reindex 180 degrees, and reconnect.
Circular rear axle companion flanges can be
indexed in 45 degree increments to fine tune the
runout condition; half-round rear axle companion
flanges are limited to two positions. Check runout
at rear of driveshaft, and if still over .89mm (.035 REPLACE REAR AXLE • END YOKE F4695-D
inch), mark high point and see Step 6. If runout is
no longer excessive, check for vibration at road
test speed, and, if still present, reindex the 7. Driveshaft balancing involves installing one or two
driveshaft slip yoke (4841) on the transmission hose clamps on the driveshaft, near the rear end
output shaft 180 degrees and road test the of a one-piece driveshaft. Best positioning of the
vehicle. If the vibration persists, proceed to Step hose clamp head(s) can be determined by
7 or driveshaft balancing procedure under trial-and-error, if special balancing equipment is
Adjustments. not available. If transducer-and-strobe equipment
is available, see Adjustments in this section for
balancing procedure.

ALL RIGHTS RESERVED
05-00-21 Axle and Driv8shaft, Service 05-00-21
8. Mark off the rear of the driveshaft into four

approximately equal sectors, and number the
marks 1 through 4. Install a hose clamp on the
driveshaft with its head at position No.1. Check
for vibration at road speed. Recheck with the
clamp at each of the other positions, to find the
position for minimum vibration. If two adjacent
positions show equal improvement, position the
clamp head between them.
NO.1
DETERMINING BEST POSITION FOR .CLAMP POSITION
NO.4--~ ~--NO.2
NO.3 F3405-1 A
9. If condition is still not acceptable, add a second

clamp at the same position and recheck vibra~ion.
If no improvement is noted, rotate the clamps In
opposite directions, equal distances from the
best position determined in Step 8. Initially,
F3407-1B
separate the clamp heads about 12mm (1 /2
inch), and recheck vibration at road speed. Driveline Angularity
Repeat the process with increasing separation Driveline angularity is the angular relationship between
until the best combination is found, or vibration is the engine crankshaft (6303), the driveshaft and the
reduced to an acceptable level. rear axle pinion. Factors determining driveline
10. Install wheels and road test, since vibration angularity include ride height (rear spring (5560», and
noticeable on the hoist may not be evident during engine mounts.
the road test. If vibration is still not acceptable, Low speed vibration, less than 72 km/h (45 mph),
replace the rear axle drive line vibration damper, especially when the vehicle is subjected to heavy
if so equipped. If road test is not acceptable, acceleration or deceleration, is an indication of
replace ring gear and pinion. improper driveline angles. When these conditio~s
exist, check the universal joints for proper seating,
mounting and operation.
Driveline Angularity
/
BOTTOM OF
FRAME
,
ENGINE
ANGLE
,
DRIVESHAFT AND COUPLING
SHAFT ANGLE
\
ENGINE CRANKSHAFT DRIVESHAFT AND COUPLING REAR AXLE PINION

CENTERLlNE SHAFT CENTERLINE CENTERLINE F--.8
ALL RIGHTS RESERVED
Driveshaft Vibrates
1. Road test vehicle to determine critical vibration
points. Note road speed, engine rpm and shift
lever positions at which vibration occurs.
2. Stop vehicle and run engine with clutch TRACTION ASSIST
depressed (automatic transmission in neutral) (TRACTION-LOK)
TORQUE TOOL
through critical speed ranges determined in T59L-4204-A
Step 1.
3. With clutch depressed, all potential engine and
clutch concerns are eliminated. If vibration
persists, the driveline must be balanced as
TORQUE WRENCH E9769-A
Traction-Lok@ Differential
SPECIAL SERVICE TOOL(S) REQUIRED Limited Slip Differential

Description Tool Number Refer to Section 05-02H for F-150 and Bronco; and
Section 05-02C for F-250-350.
Traction Assist (Traction-Lok@) Torque T59L-4204-A
Tool In-Vehicle Check
Traction Assist (Traction-Lok@) Torque T66L-4204-A
To demonstrate the proper performance of the
Tool
Traction-Lok@ differential:
A Traction-Lok@ differential can be checked for proper 1. Place one wheel on good, dry surface and the
operation without removing it from the rear axle other wheel on ice, mud or snow.
housing (4010).
2. Gradually open throttle to obtain maximum
WARNING: A VEHICLE EQUIPPED WITH A traction prior to "break-away." The ability to
TRACTION-LOK@ DIFFERENTIAL WILL ALWAYS move the vehicle will demonstrate proper
HAVE BOTH WHEELS DRIVING. IF, WHILE THE performance of a Traction-Lok@ rear axle
VEHICLE IS BEING SERVICED, ONLY ONE WHEEL assembly (4006).
IS RAISED OFF THE FLOOR AND THE REAR AXLE
3. When starting with one wheel on an excessively
IS DRIVEN BY THE ENGINE, THE WHEEL ON THE
slippery surface, a slight application of the
FLOOR COULD DRIVE THE VEHICLE OFF THE
parking brake may be necessary to help energize
STAND OR JACK. BE SURE BOTH REAR WHEELS
the limited slip feature of the differential. Release
ARE OFF THE FLOOR.
the brake when traction is established. Use light
Raise up one rear wheel and remove the wheel cover throttle on starting to provide maximum traction.
(1130). Install adapter for Traction Assist
4. If, with unequal traction, both wheels slip, the
(Traction-Lok@) Torque Tool T59L-4204-A or Traction
limited slip rear axle has done all it can possibly
Assist (Traction-Lok®) Torque Tool T66L-4204-A on
do.
the wheel hub bolts (1107).
5. In extreme cases of differences in traction, the
Using a torque wrench with the capacity of at least
wheel with the least traction may spin after the
271 N·m (200 Ib-ft), rotate the axle shaft (4234). Be
Traction-Lok@ has transferred as much torque as
sure that the transmission is in NEUTRAL, one rear
possible to the non-slipping wheel.
wheel is on the floor and the other rear wheel is raised
off the floor. The breakaway torque required to start Universal Joint Flange Runout Check, Rear
rotation should be at least 27 N·m (20 Ib-ft). The initial Axle
breakaway torque may be higher than the continuous
turning torque but this is normal.. The axle shaft should Circular
turn with even pressure throughout the check without
slipping or binding. If the torque reading is less than SPECIAL SERVICE TOOL(S) REQUIRED
specified, check the differential case (4204) for Description Tool Number
improper assembly.
Companion Flange Runout Gauge T92L-4851-B
Clamp Plate T92L-4851-C
CAUTION: This operation disturbs the pinion

bearing preload. Pinion bearing preload must be
reset if the pinion nut has been loosened or
removed for rear axle universal joint flange
(4851) reindexing or replacement.
1. Raise the vehicle on a hoist that supports the rear
axle (twin-post hoist). Refer to Section 00-02.

ALL RIGHTS RESERVED
2. Remove the driveshaft assembly. Refer to

Section 05-01.
3. Check the rear axle universal joint flange for
damage. CLAMP PLATE
T92L-4851-C
4. Position Companion Flange Runout Gauge
T92L-4851-B on rear axle universal joint flange.
E8358-A
7. NOTE: Refer to Section 05-02A for rear axle

universal joint flange Removal and Installation
procedures.
Using Dial Indicator / Magnetic Base
D78P-420 1-B or equivalent turn companion
flange runout gauge as shown to locate and mark
high spot on rear axle universal joint flange. If
flange runout exceeds 0.010 inch, remove rear
axle universal joint flange, reindex 180 degrees
E8356-B on pinion and reinstall. Check runout again. If
necessary, rotate rear axle universal joint flange
until an acceptable runout is obtained. If flange
Part runout is still more than 0.010 inch, replace rear
Item Number Description axle universal joint flange.
1 - Pilot (Part of 4851)
2 354845 Pinion Nut
3 T92L-4851-B Companion Flange Runout
Gauge
4 - Bolts (2 Req'd)
(Part of T92L-4851-C)
5 T92L-4851-C Clamp Plate
6 4851 Rear Axle Universal Joint
Flange
5. Install Clamp Plate T92L-4851-C on Runout

Gauge.
DIAL INDICATOR!
MAGNETIC BASE
D78P-4201-B
CLAMP PLATE
T92L-4851-C lA--.~_--VIEWA
E8357·A
6. Align holes in clamp plate with holes in rear axle

universal joint flange and install bolts. Snug bolts
evenly.
VIEW A E8359-B

ALL RIGHTS RESERVED
8. If excessive runout is still evident after ~

replacement of the rear axle universal joint flange,
replace the ring and pinion. Repeat the above
checks until runout is within specifications. Install
the driveshaft assembly as outlined in Section
05-01. lighten bolts to 95-130 N·m (70-95 Ib-ft).
Half-Round

COMPANION FLANGE
Gauge Pin T92T-4851-E RUNOUT GAUGE
Gauge Pin T92T-4851-F T92T-4851-D
Gauge Pin T92T-4851-G E91OD-C
Companion Flange Runout Gauge T92T-4851-D
7. NOTE: Accurate tool set-up will result in accurate
1. Raise the vehicle on a hoist. final readings.
2. Remove the driveshaft (refer to Section 05-01). Position Oiallndicator / Magnetic Base
3. Check the rear axle universal joint flange for 078P-4201-B or equivalent as shown. Adjust and
damage to the universal joint bearing locating lightly tighten mounting bolts and nuts so gauge
lugs. If the lugs are shaved (worn) or damaged, runout is .254mm (0.010 inch) or less.
replace the rear axle companion flange.
4. Insert correct size Gauge Pin, T92T-4851-E,
T92T-4851-F: or T92T-4851-G.
HALF-ROUND
REAR AXLE COMPANION
FLANGE-4851
DIAL INDICATOR!
MAGNETIC BASE
D78P-4201-B
COMPANION FLANGE
RUNOUT GAUGE
T92T-4851-0 E9101-e
8. Reposition dial indicator on edge of gauge, and

5. Position Companion Flange Runout Gauge turn rear axle companion flange / gauge as shown
T92T-4851-0 on Gauge Pin. until high spot is located.
DIAL INDICATORIMAGNETIC BASE

D78P-4201-B
COMPANION FLANGE
~
RUNOUTGAUGE
T92T-4851-D
E9099-C
6. Insert two bolts through gauge and rear axle

universal joint flange. Install two nuts and
hand-tighten.

ALL RIGHTS RESERVED
9. CAUTION: The following operation may 11. Install driveshaft as described in Section 05-0 1.
disturb the pinion bearing preload. Pinion lighten bolts to 95-130 N·m (70-95 Ib-ft).
bearing preload must be preset if the pinion
nut Is loosened or removed for companion Tooth Contact Pattern Check of Gearset
flange reindexing or replacement of rear axle 1. To check the gear tooth contact, paint the gear
companion flange. teeth with the special marking compound. A
Turn companion flange runout gauge as shown to mixture that is too wet will run and smear; too dry
locate and mark high spot on rear axle universal a mixture cannot be pressed out from between
joint flange. If flange runout exceeds .254mm the teeth.
(.010 inch), remove rear axle universal joint 2. Rotate the ring gear (use a box wrench on the
flange, reindex 180 degrees on pinion and ring gear attaching bolts as a lever) several
reinstall. Check runout again. Rotate the rear axle complete revolutions in both directions or until a
universal joint flange on the differential pinion clear tooth contact pattern is obtained.
shaft (4211) until an acceptable runout is 3. Certain types of gear tooth contact patterns on
obtained. If flange runout is still greater than the ring gear indicate incorrect adjustment.
.254mm (.010 inch), replace rear axle companion Incorrect adjustment can be corrected by
flange. readjusting the ring gear or the pinion.
4. The illustration shows acceptable tooth patterns
DIAL INDICATOR!
r"'I",..:---------- MAGNETIC BASE for all axles. In general, desirable tooth patterns
should have the following characteristics:
D78P-4201-B
a. The drive pattern should be fairly well
centered on the tooth.
b. The coast pattern should be fairly well
c. Some clearance between the pattern and the
top of the tooth is desirable.
d. There should be no hard lines where the
pressure is high.
E9103-C
10. If excessive runout is still evident after
replacement of the rear axle universal joint flange,
it will be necessary to replace the ring gear and
pinion, and repeat the checks described in Step 9
until runout is within specifications (.254mm [.010
in. ]). Refer to Section 05-02A for companion
flange replacement procedures.

ALL RIGHTS RESERVED
05·00·26 Axle and Driv8shaft, Service 05·00·26
Contact Pattern Location
PATTERN INTERPRETATION
(RING GEAR)
DRIVE SIDE COAST SIDE
NORMAL OR DESIRABLE PATTERN. THE DRIVE
HEEL TOE TOE HEEL PATTERN SHOULD BE CENTERED ON THE
#i?~
TOOTH. THE COAST PATTERN SHOULD BE CEN-
TERED ON THE TOOTH, BUT MAY BE SLIGHTLY
TOWARD THE TOE. THERE SHOULD BE SOME
CLEARANCE BElWEEN THE PATTERN AND THE
TOP OF THE TOOTH•
• ~
BACKLASH CORRECT. THINNER PINION POSI-
TION SHIM REQUIRED.
BACKLASH CORRECT. THICKER PINION POSI-
.~
TION SHIM REQUIRED.
PINION POSITION SHIM CORRECT. DECREASE
tw~
BACKLASH.
• ~
PINION POSITION SHIM CORRECT. INCREASE
BACKLASH.
. E8232·B
Inspection Before Disassembly of Axle 3. Check the ring gear and pinion teeth for signs of
scoring, abnormal wear or nicks/chips.
Axle Backlash Check
4. NOTE: On F-Series and Bronco vehicles
SPECIAL SERVICE TOOL(S) REQUIRED equipped with rear anti-lock brakes (RABS),
mount Dial Indicator with Bracketry
Description Tool Number TOOL-4201-C or equivalent on the carrier so the
Pinion Depth Gauge Set T79P-4020-A tip of the dial indicator contacts the backface of
the ring gear and pinion. There is a space
The differential case (4204) and drive pinion should be provided between the anti-lock 'speed sensor ring
inspected before they are removed from the and the ring gear and pinion for measuring ring
differential carrier casting. These inspections can help gear and pinion backface runout.
find the cause of the concern and determine the Set up a dial indicator, and check ring gear and
correction needed. pinion backlash and ring gear and pinion
1. Wipe the lubricant from the internal working parts backface runout.
and visually inspect the parts for wear or
damage.
2. Rotate the gears to see if there is any roughness
which would indicate worn or damaged bearings
or gears.

ALL RIGHTS RESERVED
05·00·27 Axle and Drlveshaft, Service 05·00·27
5. Proper ring gear and pinion must be checked Inspection After Disassembly of the Axle
using the Pinion Depth Gauge Set T79P-4020-A Thoroughly clean all parts. The pinion seal is a
which shows correct pinion shim required to synthetic rubber and must not be cleaned, soaked or
assure acceptable running condition. washed in cleaning solvents. Always use clean solvent
when cleaning bearings. Oil the bearings immediately
after cleaning, to prevent rusting. Inspect the parts for
wear or damage. If rust is present, remove with a wire
brush mounted on a power drill or equivalent. Rinse
clean with metal-prep solvent on sponge or rag to
remove all particles. With a clean sponge, coat tube
interior with Dupont 3012-5 Red Oxide Preparakote or
equivalent. Allow to dry for a minimum of one hour.
When a scored ring gear and pinion is replaced, the
axle housing should be washed thoroughly. Inspect
individual parts as outlined below.
Gears
Examine the teeth of ring gear and pinion for scoring or
excessive wear. Worn gears cannot be rebuilt to
correct a noisy condition. Gear scoring is the result of
excessive snock IQaping, vehicle loading, or the use of
an incorrect lubricant all of which contribute to the loss
of lubricating film-between the two gears. Scored
gears cannot be reused. Examine the teeth and thrust
CHECKING REAR AXLE RING GEAR surfaces of the differential gears. Wear on the hub of
AND PINION BACKLASH the differential side gear can cause a chucking noise
E4972-E known as chuckle when the vehicle is driven at low
speeds. Wear of splines, thrust surfaces, or thrust
washers, can contribute to excessive driveline
backlash.
Rear B~ake Anti-Lock Sensor
Inspect the rear brake anti-lock sensor for loose metal
particles, an,d clean if required. Note any indication of
lubricant leakage through core of rear brake anti-lock
sensor or around perimeter. Replace as required.
Anti-Lock Speed Sensor Ring
Examine the anti-lock speed sensor ring to see that it
is firmly pressed on to the differential case (4204) and
check it for damaged (dented, chipped or missing)
teeth that could result in erratic RABS performance. If
damage is found, remove and replace anti-lock speed
sensor ring.
Bearing Cups and Cone and Roller Assemblies
Check bearing cups for rings, scores, galling, or
excessive wear. Pinion bearing cups must be solidly
seated in the housing bores. Check for seating by
attempting to insert a 0.04mm (Q.0015-inch) feeler
gauge between these cups and the bottoms of their
SPEED
MAGNETIC SENSOR bores.
BASE RING When operated in the bearing cups, cone and roller
48409
assemblies must turn without roughness. Examine the
RING GEAR BACKFACE RUNOUT large roller ends for wear. If the original blend radius
REAR ANTI-LOCK BRAKE VEHICLES E7162-E has worn to a sharp edge, the bearing should be
replaced.
If inspection reveals either a worn bearing cup or a
worn cone and roller, both parts should be replaced to
avoid damage.

ALL RIGHTS RESERVED
CLEANING AND INSPECTION (Continued) ADJUSTMENTS
Universal Joint Flange, Rear Axle Axles

Be sure that the surfaces of the rear axle companion Certain rear axle (4001) and driveline concern
flange have not been damaged in removing the symptoms are also common to the engine (6007),
driveshaft or in removing the rear axle companion transmission (7003), rear wheel bearing (1225), tires,
flange from the rear axle (4001). The end of the rear and other parts of the vehicle. For this reason, be sure
axle companion flange that contacts the front that the cause of the concern is in the rear axle before
differential pinion bearing inner race or slinger washer, adjusting, repairing or replacing any of the parts. Refer
as well as the flat surface of the pinion nut to Section 00-04.
counterbore, must be smooth. Polish these surfaces if
necessary. Note also the barrel of the rear axle
companion flange (circular or half round) for any
damage which could permit the pinion seal to leak. Coupling Shaft Angle Adjustment
Roughness aggravates backlash noises and causes
wear of the rear axle companion flange and pinion nut, Check coupling shaft angle (if so equipped) and adjust
with a resultant loss in pinion bearing preload. to specification by shimming the driveshaft center
bearing support (4800) as described in this section.
Differential Housing
Make sure that the differential bearing bores are
smooth. Remove any nicks or burrs from the mounting
surfaces of the differential carrier housing. Driveshaft and Pinion Angle Adjustment
Differential Case Check the driveshaft angle and adjust to
specifications by shimming between the rear springs
Make sure that the hubs where the bearings mount are (5560) and the rear axle spring seats.
smooth. Carefully examine the differential case
bearing shoulders, which may have been damaged Adjust the pinion angle by placing tapered shims
when the bearings were removed. The bearings will between the rear springs and spring seats. On F-150,
fail if they do not seat firmly against the shoulders. a 63.5mm-(2-1 /2 inch) wide shim (Part No.
Check the fit (free rotation) of the differential side C3TZ-5A313-A or equivalent) is available for a
gears in their counterbores. 2-degree change. On Bronco, a 63.5mm-(2-1 /2 inch)
wide shim (Part No. C3TZ-5A313-E or equivalent) is
NOTE: Care should be taken to prevent damage to the available for a 3-degree change. On F-250-350, and
anti-lock speed sensor ring while handling and F-Super Duty Chassis Cab, a 76.2mm-(3-inch) wide
servicing the differential case. shim (Part No. C6TZ-5A313-B or equivalent) is
Limited Slip Differential Parts available for a 3-degree change. For F-Super Duty
Chassis, a 101. 1mm-(4-inch) wide shim is required.
Inspect the differential clutch packs for uneven or
extreme wear. The tanged clutch plates must be free
from burrs, nicks or scratches which could cause
excessive or erratic wear to the internally splined
clutch plates. The internally splined clutch plates Driveline Angle Correction
should be inspected for condition of the material, and Engine Angle Adjustments
wear. Replace the clutch plates if their thickness is
less than 1.5mm (0.058-inch) or if the material is The engine angle is adjusted by normalizing the engine
scored or badly worn. Inspect the clutch plate internal mounts. The engine mounts are normalized by
teeth for wear. Replace them, if excessive wear is loosening the engine mount nuts to frame. Raise the
evident. driveshaft up off the frame, then lower the driveshaft
and let it settle into place. Service any damaged
Clutch plates should be replaced as a set only. mounts at this time. Tighten all fasteners to the
Examine all thrust surfaces and hubs for wear. specified torque. Recheck the engine angle, if the
Abnormal wear on these surfaces can contribute to a angle is still out of specification, place shims under the
noisy rear axle. transmission-to-rear crossmember mount until the
Wheel Bearing and Seal specified angle is obtained.
Two types of rear wheel bearings (1225) are used in
truck rear axles. Straight roller bearings are used in
semi-floating rear axles, which are used in all light
trucks under 8551 GVW. The bearing rides on the axle Driveshaft Runout and Balance
shaft (4234). Vibration or shudder which is noticeable either on fast
The wheel seal on full-float axles is inboard of the inner acceleration, when coasting, or when using the engine
wheel bearing. It is identified as 1175 on Dana axles (6007) for braking, may be caused by the rear axle
and 1177 on Ford 10.25-inch axles. The Dana seal lip housing (4010) being loose on the rear suspension,
runs against the axle spindle, while the Ford seal has improper tire balance, improper driveline installation,
internal lips running against the seal internal surface. or driveline balance.
Full service procedures for these bearings and oil
seals are provided in Section 05-02D, Section
05-02G, or Section 05-02A.

ALL RIGHTS RESERVED
05-00-29 Axle and Driveshaft, Service 05-00-2S
If driveshaft components are replaced and shaft 5. With the transmission in gear, run the vehicle with
vibration is encountered after installation, disconnect the driveshaft rotating at a speedometer speed of
the driveshaft (4602) and remove the driveshaft. 64-80 km (40-50 miles); have an assistant
Rotate the rear axle companion flange 180 degrees; carefully bring a crayon, piece of chalk, or
then, reconnect the driveshaft to the driveshaft slip colored pencil up until it just barely contacts the
yoke (4841) and reinstall in vehicle. If the vibration rear end, center and front end of the driveshaft.
persists, disconnect the driveshaft at the rear axle The chalk marks will indicate the heavy side of
companion flange. Rotate the rear axle companion the driveshaft. Use caution when checking the
flange 180 degrees and reconnect the driveshaft to driveshaft near the balance weights to prevent
the rear axle companion flange. Driveshafts injury to the hands.
connected to circular rear axle companion flanges on
8.8-inch rear axles (4001) can be indexed in
45-degree increments to fine-tune the balance of the
driveline system.
If rotating the driveshaft 180 degrees does not
eliminate vibration, the driveshaft may be balanced,
using the following procedure:
1. Raise the vehicle on a twin-post hoist so that both
the front and rear axles are safely supported with
all wheels free to rotate.
2. Remove the rear wheels and tires. Reinstall
lugnuts to retain brake drums or rotors.
3. With the transmission (7003) in gear, increase
the vehicle speed to the maximum vibration level.
Note and record the speed of this vibration period
as a baseline speed.
4. Check the attachment of all rear axle shaft
universal joint bearing caps of the driveshaft to
the transmission yoke for improper installation or 6. Install two screw-type hose clamps on the
damaged rear axle shaft universal joint bearing driveshaft so that their heads are located 180
cap locating lugs. All yokes with worn, shaved, or degrees from the chalk mark, starting at the
damaged locating lugs must be replaced. pinion yoke end of the driveshaft. Tighten the
clamps.
CHALK MARK
7. CAUTION: To prevent overheating, do not

run the vehicle on the hoist for an extended
period.
Run the vehicle up to the baseline speed. If
vibration is still evidenced, rotate the clamps
approximately 45 degrees away from each other
E6116-B and test for correction of vibration.
8. If necessary, continue to rotate the clamps apart
in smaller increments until the vibration is
eliminated or begins to be reduced.
ALL RIGHTS RESERVED
9. If the vibration is not completely eliminated, In some cases, rotating the driveshaft 180
repeat the foregoing procedure and balance the degrees may decrease the vibration to an
front end of the driveshaft, checking for acceptable level. However, if the vibration level is
elimination or reduction in the vibration level. increased, install the driveshaft in its original
position and proceed to Step 4. Driveshafts
10. Reinstall wheels and tires.
connected to circular rear axle companion
11. Remove the vehicle from the hoist and road test. flanges on 8.8-inch rear axles can be indexed in
45-degree increments to fine tune the balance of
ROTATING CLAMPS the driveline system.
CHALK MARK
4. A vehicle is more sensitive to excessive
imbalance or runout at the rearward end of the
driveshaft, therefore, locate the heavy side of the
driveshaft by the use of the strobe light and
transducer, as follows:
Scribe an axial chalk line (at any radial location)
approximately 10 1.6mm (4 inches) long at the
rear of the driveshaft. Locate the transducer on
the bottom side of the carrier, and secure it in
place. Run the engine and driveline at the worst
vibration speed noted and visually note the
position of the chalk line by use of the strobe light.
This provides a starting point for the initial
location of the clamps.
Alternate Procedure
1. Road Test ' - Evaluate and record road speed at
which vibration occurs.
2. Raise vehicle on a frame contact hoist. Remove
the wheels and tires. Reinstalilugnuts to retain
brake drums or rotors. Re-evaluate by starting
the engine, engaging the transmission and
accelerating to the indicated speeds at which the
vibration was most severe during the road test.
Suspending the rear axle makes the driveline
more sensitive to vibration.
3. Disconnect the driveshaft from the rear axle
companion flange. Rotate the driveshaft 180
ES1OS·B
degrees from its original position and reinstall.
Repeat evaluation per Step 2 above.
ALL RIGHTS RESERVED
LOCATING TRANSDUCER 7. CAUTION: Do not run the engine with the

transmission engaged on the hoist for
extended periods due to the danger of
•......-----TRANSDUCER overheating the engine or transmission.
Run the engine and driveline through the speed
range. If no vibration is felt, remove the lugnuts,
install the wheels and tires and reinstall the
lugnuts in the correct position and proceed to
Step 9. However, if any vibration still exists, the
combined weight of the two hose clamp heads
may be in excess. To reduce this excess weight,
rotate the clamp heads away from each other
approximately 15 degrees (one each way from
the original position). Run the engine and driveline
and note if the vibration has been reduced.
8. Continue to rotate the clamp heads apart in
smaller angular increments until the vehicle feel of
balance (vibration) is best. At this point, install the
wheels and tires per Step 7 and road test the
E2724-18 vehicle to determine the actual degree of
improvement. If satisfactory improvement has
5. Stop the engine and rotate the driveshaft so that been obtained, proceed with Step 9. If no
the chalk line is in the same location as it was improvement has been obtained, the clamps must
noted under the strobe light. be removed and diagnosis should be redirected
to other areas, such as wheels, tires, driveline
6. Install two (stainless steel) hose clamps on the
angle, and rear axle companion flange runout. For
driveshaft. Position the clamp heads 180
additional information, refer to Diagnosis and
degrees from the transducer and tighten the
Testing in this section.
clamps.
9. When the vehicle has been corrected to a
satisfactory level, as determined by a road test
evaluation, tighten the clamps securely. Clean
thoroughly with lacquer thinner, and spray the
clamps with a commercially available black paint
for a finished appearance.
Pinion and Ring Gear Adjustment

Two separate adjustments affect pinion and ring gear
tooth contact. They are pinion location and backlash.
TRANSDUCER ~ E6106-8
ALL RIGHTS RESERVED
Individual differences in matching the rear axle housing 1. Disconnect the driveshaft (4602) from the rear
(4010) and the differential pinion bearings (4630) axle yoke and remove it from the truck.
require the use of shims to locate the pinion for correct 2. Clean the male splines of the coupling shaft using
contact with the ring gear. Refer to Section 05-02A for care not to damage the plastic coating. Fine
shim selection procedures. abrasive cloth may be required to dress and
polish the male spline. Remove all hardened
grease deposits, dirt, or rust. Inspect for worn or
galled splines. The plastic coating on the stub
spline must not be removed. Replace coupling
shaft if necessary.
ADJUSTMENT
3. Clean and inspect the female splines of the
driveshaft slip yoke, removing any hardened
grease deposits, dirt or rust. Inspect splines for
worn or galled conditions, replace driveshaft slip
yoke if necessary.
4. Apply a coating of Premium Long-Life Grease
XG-1-C or -K or equivalent meeting Ford
specification ESA-M 1C75-8 to the entire splined
stub end of the coupling shaft prior to the
assembling of the driveshaft to the coupling shaft.
5. Using a clean long handle (stencil-type) brush
apply Premium Long-Life Grease XG-1-C or -K or
ESA-M 1C75-B spread evenly on all the female
splines of the slip yoke. The spline joint must slide
freely by hand.
6. Assemble the driveshaft to the coupling shaft
with the yokes phased properly. Attach
driveshaft to rear axle yoke.
7. Using a hand type grease gun, lubricate the
driveshaft slip yoke through the zerk fitting with
ESA-M1C75-B.
E1476-F LUBRICATION
Part Axle Lubrication, Rear

Item Number Description The ability of any rear axle (4001) to deliver quiet,
1 4851 Rear Axle Universal Joint trouble-free operation over a period of years is largely
Flange dependent upon the use of good quality gear
2 4859 Drive Pinion Oil Seal lubricants. To make sure gears and bearings will last
Deflector as long as possible, use only specified hypoid gear
3 4662 Differential Drive Pinion lubricants.
Bearing Spacer Dana and Ford rear axles use WSP-M2C 197-A
4 4663 Drive Pinion Bearing (XY-80W90-QL) lubricant.
Adjustment Shim
5 4067 Differential Bearing Shim It is recommended that the lube be replaced in all rear
6 4067 Differential Bearing Shim
axles at 100,000 mile intervals, or if the rear axle has
been submerged in water, or more often under certain
extreme conditions. High Performance Rear Axle
Lubricant F1TZ-19580-B or equivalent meeting Ford
specification WSL-M2C 191-A is available for repairs
Slip-Yoke Spline and refills in situations that fall into the severe or
Vehicle noise and vibration can be caused by a seized extreme use categories. Refer to maintenance
driveshaft slip yoke (4841) spline resulting in the schedules, in Section 00-03.
rubber isolator being pulled out of the driveshaft center Dana front drive axles have different lubrication
bearing bracket. requirements for different applications.
The service resolution to minimize driveshaft slip yoke
spline contamination and ultimate seizure is as follows:
ALL RIGHTS RESERVED
• F-150-250 requires WSL-M2C191-A

(F1TZ-19580-A)
• F-350 requires WSP-M2C 197-A (XV-80W90-QL)
Draining and Filling / NOTE: A suction pump may also be used for draining
lube from the axle housing. Note that this method will
Ford Rear Axle not clean all debris which may settle at the bottom of
The filler hole is in the differential carrier casting. Fill the carrier.
F-150 rear axles (4001) 6.35-14.28mm (1 /4 to 9/ 16
inch) below bottom of the hole. Dana Front and Rear Axles
To check F-250-350 rear axles for proper . The lubricant level in these axles may vary depending
lubricant level, the filler plug should be backed on internal casting variations, spring orientation, or
out slowly. If seepage occurs around the threads flatness of the floor or hoist involved, as well as the
of the plug, immediately turn the plug back in to amount of fill. During manufacture, axles are filled by
avoid any drainage. This condition indicates that volume, not to a specific level. Dealer inspection of
the specified factory fill amount of lubricant is in rear axle lubricant level is not an authorized element of
the rear axle. Service fill is level with bottom of vehicle preparation. The only times a dealer should
filler hole. check lubricant levels are: 1) when a leak is suspected
or observed, or 2) when an axle repair requires
Dana Rear Axles draining and refilling.
Dana rear axles do not have a drain plug. The axle These Dana rear axles have a proper lubricant fill level
housing cover (4033) should be loosened and of 6.35-19.05mm (0.25-0.75 inch) below the bottom
removed from the axle housing to allow drainage. The of the fill hole in the axle housing cover. Dealers should
RTV Sealer must be removed from the axle housing avoid overfilling the rear axle above this range
cover and axle housing. Reseal with Silicone Rubber, because overfilling can cause foaming and raise the
E7TZ-19562-A or equivalent meeting Ford temperature of the lubricant, leading to lubricant
specification ESL-M4G273-A. oxidation and eventual gear or bearing failure in
extreme cases. The extra lubricant may also be
expelled through the rear axle vent hose.
SPECIFICATIONS
REAR DRIVELINE ANGLES, BRONCO 4x4 (CURB LOAD)

Rear Axle
Rear
Blocked Coupling Drive-
Ride Engine Shaft shaft Pinion
Wheel Trans- Rear GVW Height Angle Angle Angle Angle
Base Engine (L) mission Spring Axle Ratio Capacity (mm) (Oeg.) (Oeg.) (Oeg.) (Oeg.)
2660 5.0/5.8 M50D F4TA-DSE 3.55/4.10 3800 155.65 5.5 - 11.9 10.8
2660 4.9/5.0/5.8 E40D F4TA-DSE 3.08/3.55 3800 155.65 5.5 - 12.5 10.8
REAR DRIVELINE ANGLES, F-150 4x4 (CURB LOAD)

Rear Axle
Rear
Blocked Coupling Orlve-
Wheel Rear Axle GVW Height Angle Angle Angle Angle
Base Engine (L) Transmission Spring Ratio Capacity (mm) (Oeg.) (Oeg.) (Oeg.) (Oeg.)
2967 4.9/5.0 M50D F4TA-LB 3.08/3.55 3800 186.08 5.5 - 13.7 4.9
2967 4.9/5.0/5.8 E40D F4TA-LB 3.55 3800 186.08 5.5 - 14.3 4.9
2967 5.0 4R70W F4TA-LB 3.31/3.55 3800 186.08 5.5 - 13.6 4.9
3378 4.9/5.0 M50D F4TA-LB 3.08/3.55 3800 186.08 5.5 - 9.3 4.9
3378 5.0 4R70W F4TA-LB 3.31/3.55 3800 186.08 5.5 - 9.0 4.9
3378 4.9/5.0/5.8 E40D F4TA-LB 3.08/3.55 3800 186.08 5.5 - 9.5 4.9
(Continued)

ALL RIGHTS RESERVED
REAR DRIVELINE ANGLES, F-150 4x4 (CURB LOAD) (Cont'd)

Rear Axle
Rear
Blocked Coupling Drlve-
Base Engine (l) Transmission Spring Ratio Capacity (mm) (Deg.) (Deg.) (Deg.) (Deg.)
3378 4.9/5.0 M50D F4TA-JB 3.08/3.55 3800 181.52 5.5 - 9.1 4.9
3378 5.0 4R70W F4TA-JB 3.31/3.55 3800 181.52 5.5 - 9.0 4.8
3378 4.9/5.0/5.8 E40D F4TA-JB 3.08/3.55 3800 181.52 5.5 - 9.3 4.8
3526 4.9/5.0 M50D F4TA-JB 3.08/3.55 3800 181.52 5.5 - 8.2 4.8
3526 5.0 4R70W F4TA-JB 3.31/3.55 3800 181.52 5.5 - 8.1 4.8
3526 5.0/5.8 E40D F4TA-JB 3.08/3.55 3800 181.52 5.5 - 8.3 4.8
3937 4.9/5.0 M50D F4TA-JB 3.08/3.55 3800 181.52 5.5 4.7 7.8 4.8
3937 5.0 4R70W F4TA-JB 3.31/3.55 3800 181.52 5.5 4.8 7.8 4.8
3937 5.0/5.8 E40D F4TA-JB 3.08/3.55 3800 181.52 5.5 4.6 7.8 4.8

Rear Axle
Rear
3937 5.8/7.3/7.5 E40D F2TA-VB 3.55/ 4.10~ 6250 229.7 5.5 7.9 9.2 7.0
3937 5.8 M5HD b F2TA-VB 3.55/ 4.10~ 6250 229.7 5.5 7.7 9.2 7.0
3937 7.3/7.5 M5~Dc F2TA-VB 3.55/4.10· 6250 229.7 5.? 7.5 9.4 6.7
3937 5.8/7.5 C6 F2TA-VB 3.55/ 4.10~ 6250 229.7 5.5 7.4 9.3 6.7
3378 5.8/7.5 M5HD b E3TA-TA 3.55/ 4.10~ 6250 213.4 5.5 - 11.4 6.7
3378 5.0/7.3/7.5 E40D E3TA-TA 3.55/4.10· 6250 213.4 5.5 - 11.8 6.7
3378 5.8/7.5 C6 F3TA-TA 3.55/4.10· 6250 213.4 5.5 - 11.1 6.7
3378 7.3 M5HO b F3TA-TA 3.55/4.10· 6250 213.4 5.5 - 11.2 6.7
a 7.30-4. 10 only.
b Wide ratio / close ratio.
c Close ratio.

Rear Axle
Rear
Blocked Coupling Drlve-
3378 5.8/7.3/7.5 E400 F3TA-TA 3.55/4.10 6250 183.92 5.5 - 11.2 5.9
3378 5.8/7.5 C6 F3TA-TA 3.55/4.10 6250 183.92 5.5 - 10.5 5.9
3378 5.8/7.5 M5HD 8 F3TA-TA 3.55/4.10 6250 183.92 5.5 - 10.9 5.9
3378 7.3 M5HOb F3TA-TA 3.55/4.10 6250 183.92 5.5 - 10.7 5.9
a Wide ratio / close ratio.
b Close ratio.
ALL RIGHTS RESERVED

Rear Axle
Rear
Wheel Engine Rear Axle GVW Height Angle Angle Angle Angle
Model Base (l) Transmission Spring Ratio Capacity (mm) (Oeg.) (Oeg.) (Oeg.) (Oeg.)
REG. 2967 4.9/5.0 M50D F4TA-RA 2.73 3800 185.8 5.5 - 8.4 6.0
CAB 3.08
3.55
REG. 2967 4.9/5.8 E40D F4TA-RA 2.73 3800 185.8 5.5 - 8.9 6.0
CAB 3.08
3.55
REG. 2967 5.0 4R70W F4TA-RA 2.73 3800 185.8 5.5 - 8.4 6.0
CAB 3.08
3.55
REG. 3378 4.9/5.0 M50D F4TA-NB 2.73 3800 185.8 5.5 - 6.4 6.0
CAB 3.08
3.55
REG. 3378 4.9/5.0 M50D F4TA-NB 2.73 3800 185.8 5.5 5.0 7.6 6.0
CAB 3.08
3.55
REG. 3378 4.9 M5HD F4TA-NB 2.73 3800 185.8 5.5 5.1 7.6 6.0
CAB 3.08
3.55
REG. 3378 4.9/5.0/ E40D F4TA-NB 2.73 3800 185.8 5.5 - 6.5 6.0
CAB 5.8 3.08
3.55
REG. 3378 5.0 4R70W F4TA-NB 2.73 3800 185.8 5.5 - 6.4 6.0
CAB 3.08
3.,55
REG. 3378 4.9/5.0 M50D F4TA-GA 2.73 3800 192.1 5.5 - 6.6 6.1
CAB 3.08
3.55
REG. 3378 4.9/5.0 M50D F4TA-GA 2.73 3800 192.1 5.5 5.0 7.9- 6.1
CAB 3.08
3.55
REG. 3378 4.9 M5HD F4TA-GA 2.73 3800 192.1 5.5 5.1 7.9 6.1
CAB 3.08
3.55
REG. 3378 4.9/5.0/ E40D F4TA-GA 2.73 3800 192.1 5.5 - 6.7 6.1
CAB 5.8 3.08
3.55
REG. 3378 5.0 4R70W F4TA-GA 2.73 3800 192.1 5.5 - 6.6 6.1
CAB 3.08
3.55
SUPER 3526 4.9/5.0 M50D F4TA-GA 2.73 3800 192.1 5.5 6.6 7.6 6.1
CAB 3.08
3.55
SUPER 3526 4.9/5.0/ E40D F4TA-GA 2.73 3800 192.1 5.5 6.6 7.7 6.1
CAB 5.8 3.08
3.55
SUPER 3526 5.0 4R70W F4TA-GA 2.73 3800 192.1 5.5 6.6 7.6 6.1
CAB 3.08
3.55
SUPER 3937 4.9/5.0 M50D F4TA-GA 2.73 3800 192.1 5.5 3.4 6.7 6.1
CAB 3.08
3.55
(Continued)

ALL RIGHTS RESERVED
REAR DRIVELINE ANGLES, F-150 4x2 (CURB LOAD) (Cont'd)

Rear Axle
Rear
Model Base (L) Transmission Spring Ratio Capacity (mm) (Oeg.) (Oeg.) (Oeg.) (Oeg.)
SUPER 3937 4.9/5.0/ E40D F4TA-GA 2.73 3800 192.1 5.5 3.1 7.4 6.1
CAB 5.8 3.08
3.55
SUPER 3937 5.0 4R70W F4TA-GA 2.73 3800 192.1 5.5 3.4 7.3 6.1
CAB 3.08
3.55

Rear Axle
Rear
REG. 3378 4.9/5.0 M50D F4TA-KB 3.55 5300 190.64 5.5 - 7.0 7.2
CAB 4.10
REG. 3378 4.9/5.0 M50D F4TA-KB 3.55 5300 190.64 5.5 5.3 8.3 7.2
CAB 4.10
REG. 3378 4.9 M5HD 8 F4TA-KB 3.55 5300 190.64 5.5 5.4 8.3 7.2
CAB 4.10
REG. 3378 4.9/5.8 E40D F4TA-KB 3.55 5300 190.64 5.5 - 7.1 7.2
CAB 4.10
REG. 3378 5.0 4R70W F4TA-KB 3.55 5300 190.64 5.5 - 7.0 7.2
CAB 4.10
HDREG. 3378 4.9/5.8/ M5HD 8 F3TA-TA 3.55 6250 199.07 5.5 5.4 10.0 6.3
CAB 7.5 4.10
HDREG. 3378 7.3 M5HD b F3TA-TA 3.55 6250 199.07 5.5 5.4 10.3 6.3
CAB 4.10
HDREG. 3378 5.0/7.3/ E40D F3TA-TA 3.55 6250 199.07 5.5 - 8.1 6.3
CAB 7.5 4.10
HDREG. 3378 4.9/5.8 C6 F3TA-TA 3.55 6250 199.07 5.5 - 8.0 6.3
CAB 4.10
HDREG. 3378 5.8/7.5 M5HD 8 E4TA-SA 3.55 6250 173.35 5.5 5.4 9.5 5.9
CAB 4.10
HDREG. 3378 7.3 M5HD b E4TA-SA 3.55 6250 173.35 5.5 5.4 9.5 5.9
CAB 4.10
SUPER 3937 5.8/7.3/ E40D F3TA-TA 3.55 6250 199.07 5.5 4.4 8.2 6.3
CAB 7.5 4.10
SUPER 3937 4.9/5.8 C6 F3TA-TA 3.55 6250 199.07 5.5 4.5 8.0 6.3
CAB 4.10
SUPER 3937 5.8/7.5 M5HD 8 F3TA-TA 3.55 6250 199.07 5.5 4.6 8.0 6.3
CAB 4.10
SUPER 3937 7.3 M5HD b F3TA-TA 3.55 6250 199.07 5.5 4.7 8.0 6.3
CAB 4.10
SUPER 3937 5.8/7.5 M5HD 8 E4TA-SA 3.55 6250 173.35 5.5 4.6 7.7 5.9
CAB 4.10
SUPER 3937 7.3 M5HD b E4TA-SA 3.55 6250 173.35 5.5 4.7 7.7 5.9
CAB 4.10
a Wide ratio/ close ratio.
b Close ratio.

ALL RIGHTS RESERVED
REAR DRIVELINE ANGLES, F·350 4x2

Rear Axle
Rear
REG. 3378 5.8/7.3/ E400 E4TA-SA 4.10 7400 173.35 5.5 - 8.0 5.9
CAB 7.5
REG. 3378 5.8/7.5 C6 E4TA-SA 4.10 7400 173.35 5.5 - 7.9 5.9
CAB
REG. 3378 5.8/7.5 M5H0 8 E4TA-SA 4.10 7400 173.35 5.5 5.4 9.3 5.9
CAB
REG. 3378 7.3 M5HO b E4TA-SA 4.10 7400 173.35 5.5 5.4 9.3 5.9
CAB
CREW 4278 5.8/7.3/ E400 F3TA-TA 4.10 6250 199.07 5.5 4.4 6.1 6.3
CAB 7.5
CREW 4278 4.9/5.8 C6 F3TA-TA 3.55/4.10 6250 199.07 5.5 4.5 6.1 E?3
CAB
CREW 4278 5.8/7.3/ M5HO F3TA-TA 4.10 6250 199.07 5.5 4.6 6.0 6.3
CAB 7.5
CHAS. 3475 4.9/5.8/ M5H0 8 F4TA-HA 4.10 8250 156.74 5.5 5.3 7.3 4.6
CAB 7.3/7.5
CHAS. 3475 4.9/5.8 C6 F4TA-HA 3.55/4.1C 8250 156.74 5.5 5.3 7.3 4.6
CAB
CHAS. 3475 5.8/7.3/ E400 F4TA-HA 4.10 8250 156.74 5.2 5.2 7.4 4.6
CAB 7.5
CHAS. 3475 7.3 M5HO b F4TA-HA 4.10 8250 156.74 5.5 5.4 7.3 4.6
CAB
CHAS. 4085 4.9/5.0/ M5H0 8 F4TA-HA 4.10 8250 156.74 5.5 4.4 5.7 4.6
CAB 7.3/7.5
CHAS. 4085 4.9/5.8 C6 F4TA-HA 3.55/4.10 8250 156.74 5.5 4.1 5.8 4.6
CAB
CHAS. 4085 5.8/7.3/ E400 F4TA-HA 4.10 8250 156.74 5.5 4.0 5.8 4.6
CAB 7/5
CHAS. 4085 7.3 M5HO b F4TA-HA 4.10 8250 156.74 5.5 4.4 5.7 4.6
CAB
SUPER 3937 7.3/7.5 E400 F3TA-TA 4.10 7400 199.07 5.5 4.4 8.2 6.3
CAB
SUPER 3937 7.3 M5HO b F3TA-TA 4.10 7400 199.07 5.5 4.7 8.1 6.3
CAB
SUPER 3937 7.3/7.5 M5H0 8 F3TA-TA 4.10 7400 199.07 5.5 4.8 8.1 6.3
CAB
SUPER 3937 7.3/7.5 C6 F3TA-TA 4.10 7400 199.07 5.5 4.5 8.7 6.3
CAB
a Wide ratio.
b Close ratio.
1995 F-150, F-250, F-350, Bronco, F-Super Outy Powertrain, Orivetrain July 1994

ALL RIGHTS RESERVED
REAR DRIVELINE ANGLES, F-SUPER DUTY (CURB LOAD)

Rear Axle
Rear
Base (l) Transmission Spring Ratio Capacity (mm) (Deg.) (Deg.) (Deg.) (Deg.)
3475 7.3 M5HD F4TA-HA 4.10 11000 156.74 5.5 - - 4.6
4.63
5.13
3475 7.3/7.5 E40D F4TA-HA 4.10 11000 156.74 5.5 - - 4.6
4.63
5.13
4085 7.3 M5HD F4TA-HA 4.10 11000 156.74 5.5 - - 4.6
4.63
5.13
4085 7.3/7.5 E40D F4TA-HA 4.10 11000 156.74 5.5 4.0 5.6 4.6
4.63
5.13
3475 7.5 M5HD 8 F4TA-HA 4.10 11000 156.74 5.5 5.3 7.3 4.6
4.63
5.13
4085 7.5 M5HD b F4TA-HA 4.10 11000 156.74 5.5 4.4 5.4 4.6
4.63
5.13
a Close ratio.
b Wide ratio / close ratio.
FRONT DRIVESHAFT F-1So-2S0-3S0 4x4 (CURB LOAD)

Front Axle
Engine Pinion
GVW Angle Front Drlveshaft Angle
Model Wheelbase Engine (l) Transmission Type Capacity (Degrees) Angle (Degrees) (Degrees)
Bronco and All All C6 Twin 3800 Lb. 5.5 0.03 4.39
F150 (4x4) ZF-HD I-Beam 5.5 0.01 4.39
4R70W W/Coil 5.5 -0.04 4.39
ZF-LD/R2 Spring 5.5 -0.14 4.39
E40D 5.5 -0.46 4.39
5.5 -0.09 4.39
F-250 (4x4) All All C6 Twin 4600 Lb. 5.5 2.79 6.73
ZF-HD I-Beam 5.5 2.77 6.73
4R70W wlLeaf 5.5 2.69 6.73
ZF-LD/R2 Spring 5.5 2.54 6.73
E40D 5.5 2.06 6.73
5.5 2.45 6.73
F-350 (4x4) All All All Mono-Beam 5000 Lb. 5.5 2.50 4.50
DRIVESHAFT - TORQUE LIMITS

Torque limits
Description Bolt Size N·m (lb-Ft)
Bolt Yoke to Coupling Shaft 5/8-18 201-222 8
148-1648
3/4-16 238-325 175-240
7/8-14 339-406 250-300
1-2 216 160
Nut - Rear Axle Shaft Universal Joint Kit - U-Bolt 5/16-18 11-20 8-15
3/8-18 24-35 18-26
7 116-20 41-54 30-40
Coupling Shaft Driveshaft Center Bearing 7 116-14 51-73 38-54
Bracket-to-Driveshaft Center Bearing Support
Bolt - Drive Shaft Rear Axle Shaft Universal Joint 1/2-20 123-149 91-110
Flange to. Rear Yoke
(Continued)

ALL RIGHTS RESERVED
DRIVESHAFT - TORQUE LIMITS (Cont'd)

Torque Limits
Description Bolt Size H·m (Lb-Ft)
Bolt and Nut - Rear Axle Shaft Universal Joint 1/2-20 95-129 61-70
Driveshaft to Circular Rear Axle Universal Joint Flange M12 x 1.75 x 27.0 83-118 70-95
Double Cardan Driveshaft and Coupling 5/16-24 28-33 21-24
Shaft-to-Transfer Case Bolts
Driveshaft and Coupling Shaft-to-Fro,nt and Rear Axle 5/16-18 11-20 8-15
U-Bolt Nuts
Bolt - Strapb 5/16-24 34-54 25-40
a Dana axle.
b F-250 H.D. and F-350 with M5HD transmission and F-Super Duty.
DANA AXLE TORQUE LIMITS

Axle Model
60 70 80
Description H·m Lb-Ft H·m Lb-Ft H·m Lb-Ft
Pinion Shaft Nut 339-366 250-270 339-366 250-270 596-677 440-500
Differential Bearing Cap Bolts 109-122 80-90 109-122 80-90 109-122 80-90
Ring Gear Attaching Bolts Grade 8 136-163 100-120 136-163 100-120 - -
Ring Gear Attaching Bolts Grade 9 169-183 125-135 169-183 125-135 272-325 200-240
Oil Filler Plug - 114 Inch Recess Drive 20-33 15-24 20-33 15-24 20-33 15-25
U-Joint Bolts 21-27 15-20 21-27 15-20 - -
Cover to Housing Bolts 41-54 30-40 41-54 30-40 41-54 30-40
ENGINE ANGLE TO HORIZONTAL - F-SUPER DUTY COMMERCIAL STRIPPED CHASSIS

Rear Axle
Rear
Spring
(Auxiliary Blocked Coupling Rear
Rear Ride Engine Shaft Drlveshaft Pinion
Wheel Spring Is Ring GVW Height Angle Angle Angle Angle
Base Engine(L) Transmission Standard) Gear Capacity (mm) (Deg.) (Deg.) (Deg.) (Deg.)
158 7.3 M5HD E9TD-CA 11.25 11000 254 5.5 6.1 8.9 5.5
158 7.3 E40D E9TD-CA 11.25 11000 254 5.5 6.2 9.0 5.5
178 7.3 M5HD E9TD-CA 11.25 11000 254 5.5 5.0 8.1 5.0
178 7.3 E40D E9TD-CA 11.25 11000 254 5.5 4.9 8.3 5.0
. ENGINE ANGLE TO HORIZONTAL - F-SUPER DUTY MOTORHOME CHASSIS

Rear Axle
1st 2nd
Blocked Coupling Coupling Rear
Ride Engine Shaft Shaft Drlveshaft Pinion
Wheel Engine Rear Ring GVW Height Angle Angle Angle Angle Angle
Base (L) Transmission Spring Gear .Capacity (mm) (Deg.) (Deg.) (Deg.) (Deg.) (Deg.)
178 7.5 E40D E9TD-AE 11.25 11000 171 5.5 4.4 N/A 5.7 3.4
190 7.5 E40D E9TD-AE 11.25 11000 171 5.5 4.4 N/A 4.6 3.4
208 7.5 E40D E9TD-AE 11.25 11000 171 5.5 4.1 3.0 4.8 3.4
228 7.5 E40D E9TD-AE 11.25 11000 171 5.5 3.7 2.3 4.3 3.4

ALL RIGHTS RESERVED
TORQUE SPECIFICATIONS - FORD RING GEAR AND

PINION BOLTS
8.8 Inch 95-115 70-85
10.25 Inch 136-163 100-120
FRONT AND REAR AXLE lUBRICANT CAPACITIES

Approximate Capacity
Axle Model Vehicle U.S. Pints Imperial Pints Liters
Ford Axle - 8.8 Inch Ring Gear· F-150 / Bronco 5.5 4.6 2.6
Ford Axle 10.25 Inch Ring Gearb F-250-350 (4x2) - Dual Rear Wheels 7.4 6.1 3.5
Ford Axle 10.25 Inch Ring Gearb F-250-350 (4x4) 7.4 6.1 3.5
Dana 441FS - FrontC F-150 (4x4), Bronco 3.6 3.0 1.7
d
Dana 50-IFS - Front F-250 (4x4) HD 3.8 3.2 1.8
Dana 60 - Front F-350 (4x4) 5.9 4.9 2.8
Dana 80 - Rear F-Super Duty Chassis Cab, Commercial 8.25 6.8 3.9
Stripped Chassis and Motor Home
Chassis
a Add 2 U.S. ounces of Additive Friction Modifier, F3TZ-19B546-MA (WSP-M2C196-A) or equivalent to Ford 8.8-inch limited slip rear axles
(5 U.S. ounces for Lightning trucks).
b Add 4 oz. of Additive Friction Modifier, F3TZ-19B546-MA (WSP-M2C 196-A) or equivalent to Ford 10.25-inch ring gear limited slip axles.
c Add 2 U.S. ounces of Additive Friction Modifier, C8AZ-19B546-A (EST-M2C118-A) or equivalent to Dana front drive axle with limited slip
differential.

Tool Number/ Tool Number /
Description illustration Description Illustration
T68P-4602-A T79P-4020-A
Pinion Angle Level Gauge Pinion Depth Gauge Set
, ~
I{ Il'1I J
T88P-4802-A
~~~ RD
lit. ~ .. ~,
T57T-4851-B
~
~
Companion Flange Holding Tool
f!
..
T79P-4020-A
T57T-4851-8
T92L-4851-B
T78P-4851-A Companion Flange Runout
®
Companion Flange Holding Tool Gauge
T92L-4851-B
T92L-4851-C
(Continued)
T78P-4851·A Clamp Plate
lI@t T92L·4851·C
T92T-4851-0
Companion Flange Runout
Gauge
~~e~ o e
T92T-4851.0
(Continued)

ALL RIGHTS RESERVED

(Continued)

Tool Number/ Tool Number Description
D78P-4201-B Dial Indicator / Magnetic Base
T92T-4851-E
Gauge Pin
~ T92T-4851-E Model
ROTUNDA EQUIPMENT
Description
T92T-4851-F 006-01400 Electronic Strobe Balancer

Gauge Pin
~ T92T-4851-F
T92T-4851-G
~auge Pin
~ T92T·4851-G
T59L-4204-A
Traction Assist (Traction-Lok~)
Torque Tool .
'~
T59l-4204-A
T66L-4204'-A
Traction Assist (Traction-Lok~)
~
Torque Tool
T86l-4204-A

ALL RIGHTS RESERVED
:>5·01·1 Driveshaft 05·01·1
SECTION 05·01 Driveshaft

VEHICLE APPLICATION ••••••••••••••••••.••••••••••••••••••••••••••05-01-1 REMOVAL AND INSTALLATION (Cont'd.)
DESCRIPTION AND OPERATION One·Plece •••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 05-01-9
Drlveshaft••••••••••••••••••••••••••••••••••.••••••••••••..••••••.•••••• 05-01-1 DISASSEMBLY AND ASSEMBLY
Drlveshaft with Double Cardan U·Jolnt ••••••••••••••••••• 05-01-6 Center Bearing ••••••••••••••••••••.•••••••.•••••••••••••••••••••••05-01-16
Drlveshaft with Single Cardan U·Jolnt •••••••••••••••••.•• 05-01-3 Driveshaft, Double Cardan Universal
Drlveshaft, Front Axle ••.••••••••••••••••••••••••••••••••••••••••• 05-01-6 Joint •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• OS-01-14
Universal Joint•••••••••••••••••••••••••••••••••.•.••••.•.••••.••••••• 05-01-5 Drlveshaft, Single Cardan Universal
DIAGNOSIS AND TESTING Joint •••••••••••••..•••••••••••••••••••••••••••••••••••••••••••••••••05-01-12
Drlveshaft••••••••••••••••••••.••••••••••••••••••..•.•••••••••••••••••.• 05-01-8 Slip Between Center Drlveshaft ••••••••••••••••••••••••••• OS·01·17
REMOVAL AND INSTALLATION ADJUSTMENTS
Drlveshaft, Front ••••••.••••••••••••••••••••••••••••••••..•••••••.•• 05-01-8 Drlvellne Support Plate, AdJustable •••••••••••••••••••••• OS-01-19
With Double Cardan U-Jolnt •••••••••••••••••••••••••••••••• 05-01-8 F·Super Duty Commercial Chassis •••••••••••••••••••• OS-o1-19
Drlveshaft, Rear ••••••••••••••••••••••••••••••••••••••••••••••••••••• 05·01·9 F·Super Duty Motorhome Chassls ••••••••••••••••••••• OS-01-20
Drlveshaft, Two· or Three·Plece, F·Super Drlveshaft Alignment ••••••••••••••••.•••••••••••••••••••••••••• OS-01-19
Duty Commercial Chassis and Motorhome SPECIFICATIONS •••••••••••••••••••••••••••••••••••.•••••••••••••••• OS-01-21
Chassis Vehicles •••••••.••••••••••••••••••••.•••••••••••••• 05-01-10 SPECIAL SERVICE TOOLS/EQUIPMENT •••••••••••••••••• 05-01-22
Drlveshaft/Coupllng Shaft, Two-Piece
(Except F·Super Duty, Commercial
Chassis and Motorhome Chassis) ••••.••••••••••••• 05·01-10
VEHICLE APPLICATION
F-150, F-250, F-350 4x2, 4x4, F-Super Duty Chassis
Cab, Motorhome Chassis and Bronco Vehicles
Driveshaft
The driveshaft (4602) is a tubular shaft which is used
to transfer torque from the engine, through the
transmission to the ring gear and pinion in the rear axle
(4001), which transmits the torque to the wheels.
Driveshafts differ in length, diameter, and type of slip
and axle attachment, to accommodate various
wheelbase and powertrain combinations.
Two-Piece Drlvellne System
COUPUNG SHAFT SUPPORT

BRACKET CENTER BEARING
DRIVESHAFT AND
SUP YOKE El231·A

ALL RIGHTS RESERVED
05-01-2 Driveshaft 05-01-2
DESCRIP~IONAND OPERATION (Continued)
Coupling Shaft/Center Bearing
EIZIZ·A
Part Part
1 - Dust Slinger (Part of 4800) 7 - Center Bearing
2 - Lip (Part of 4800) (Part of 4800)
3 - Grease Seal (Part of 4841) 8 4A499 Driveshaft Center Bearing
Bracket
4 4841 Driveshaft Slip Yoke
5 - Bearing Retainer Ring
9 - Coupling Shaft
(Part of 4R602)
(Part of 4800)
6 - Rubber Insulator
(Part of 4800)
(Continued)
Coupling Shaft
VIEWY
E8233-B
Part Part
1 4R602 Driveshaft and Coupling 3 - Rubber Insulator
Shaft (Part of 4~OO)
2 - Dust Slinger (Part of 4800) 4 4A499 Driveshaft Center Bearing
Bracket
(Continued)
, (Continued)

ALL RIGHTS RESERVED
05-01-3 Driv8shaft 05-01-3
Part Part
5 - Bearing Shield (Retainer) 8 - Blind Spline (Part of 4817)
(Part of 4800) A - 12.70mm (1 /2 Inch) Installed
6 - Bearing (Part of 4800) with Deep Flange Toward
7 - Splined Stub Shaft End Stub Shaft End (Rear)
(Part of 4817)
(Continued)
Drlveshaft
BLIND SPLINE
GREASE SEAL WITH

GREASE FITTING ~
YEWZ
\.--J6------.-
YEWZ
Driveshaft with Single Cardan U-Joint Others use a coupling shaft in conjunction with a
The driveshaft or coupling shaft used on F-150, F-250, driveshaft (4602). Care must be taken to align the
F-350, F-Super Duty Chassis Cab, Commercial shafts as shown in the illustrations. The two-piece
Chassis, Motorhome Chassis and Bronco vehicles is driveline system incorporates a "necked down"
composed of universal joints (U-joints), connecting coupling shaft stub with a blind spline feature which
shafts, attaching flanges, and driveshaft slip yokes assures positive phasing action. The "blind spline"
(4841). The number of shafts and U-joints used feature is not used on the F-Super Duty Commercial
depends on vehicle application. and Motorhome Chassis.
Some vehicles use a one-piece slip yoke type
driveshaft. A universal joint and driveshaft slip yoke
are located at the transmission end of the shaft, where
they are held in alignment by a bushing in the extension
housing (7A039). The driveshaft slip yoke and
transmission output shaft permit fore and aft
movement of the driveshaft as the rear axle (4001)
moves up and down. This provides smooth
performance during vehicle operation. An extension
housing seal at the extension housing prevents
leakage and protects the driveshaft slip yoke from
dust, dirt and other harmful material. A second
universal joint mates with the rear axle companion
flange at the rear axle.

ALL RIGHTS RESERVED
05-01-4 Driveshaft 05-01-4
One-Piece Driveshaft Slip Yoke
ONE PIECE DRlVE8HAFT

SUP YOKE DESIGN
SUP YOKE ASSEMBLY
-
FRONT OF VEHICLE
PARnALOR SUP YOKE WITH

NON-COUNTIRBORE COUNTERBORE/PILOT
SUP YOKE
LOWINER11A WITH DAMPER HIGH INERTIA
Part Part
1 382836-S 100 Nut 9 386867-S U-Bolt
2 4635 Universal Joint 10 4851 Rear Axle Companion
3 - Snap Ring (Part of 4635) (Universal Joint) Flange
(Half-Round)
4 - Bearing Cup (Part of 4635)
11 4859 Dust Seal
5 - Seal (Part of 4635)
6 - Spider (Part of 4635)
13 - Counter Bore / Pilot
7 4602 Driveshaft (Part of 4841)
8 375646-S2 Nut 14 - Damper (Part of 4841)
(Continued)

ALL RIGHTS RESERVED
05-01-5 Driveshaft 05-01-5
Driveshafl, Disassembled View
E4882-D
Part Part
1 4851 Driveshaft Rear Axle 5 - Snap Ring (Part of 4635)
Companion Flange 6 - Bearing (Part of 4635)
2 4866 Driveshaft Flange Yoke 7 - Seal (Part of 4635)
3 N800594-S 100 Bolt 8 - Spider (Part of 4635)
4 4635 U-Joint 9 4602 Driveshaft
(Continued) 10 4841 Driveshaft Slip Yoke
Universal Joint
The universal joints (U-joints) are lubed for life except
on commercial and motorhome chassis vehicles. Two
types of universal joint kits are used. on Ford light
trucks: Dana design and Ford design. The designs are
similar. The universal joints are equipped with a nylon
thrust washer at the base of the bearing cup. This
thrust washer controls end play, positions the needle
bearings and improves grease movement. Parts are
not interchangeable between Dana and Ford design
universal joint kits.
CAUTION: Universal joint components from
different manufacturers or new and used
universal joint kits should never be mixed.
Universal joints are to be installed as complete
assemblies only.
E8739-B All two- and three-piece driveshaft vehicles are
equipped with driveshaft center bearing supports
Part (4800) that are prelubricated and sealed for life.
Item Number Description U-joints and driveshaft slip yokes (4841) equipped
1 - Bearing Cup (Part of 4635) with grease fittings should be lubricated at the
2 - Thrust Washer (Part of 4635) intervals specified in Section 00-03. U-joint bearings
are retained on the U-joints spiders by snap rings and
3 - Needle Rollers
(Part of 4635) U-bolts or straps on some applications.
4 - Grease Seal (Part of 4635) Two different attaching systems are incorporated to
5 - Trunnion (Part of 4635) attach the driveshaft (4602) to the drive axle.
6 - Spider (Part of 4635) Depending on application, either a driveshaft flange
yoke (4866) is bolted to the (circular) companion
flange, or a universal joint is attached to the rear axle
companion flange by means of U-bolts, or bolts with
straps.

ALL RIGHTS RESERVED
05-01-6 Driveshaft 05-01-e
Driveshaft with Double Cardan U-Joint

Part
NOTE: Double Cardan driveshaft center yoke (4784)
requires lubrication.
NOTE: All driveshafts are balanced. Therefore, if the
5 - Centering Spring
(Part of 4635)
vehicle is to be undercoated, cover the driveshaft 6 78214 Transfer Case Yoke (Flange)
(4602) to prevent undercoating material from getting
on the shaft.
The driveshaft, applicable to Bronco rear driveshaft SLEEVE NO. 310048
and F-350 4x4 front driveshaft vehicles, is of the ~ BUSHING NO. 32412B
~)
double Cardan-type which incorporates two U-joints, a
driveshaft centering socket yoke (4782), and a
driveshaft centering socket yoke at the transfer case
end of each shaft. A single U-joint is used at the axle
f STEM NO. 324128
LUBRICANT ADAPTER
end of the shafts. All U-joints are lubed for life, and do ALEMITE NO. 6783 ADAPT!R DETAI LS
not require scheduled maintenance.
DOUBLE CAADAN JOINT E2707·1F
Driveshaft, Front Axle

NOTE: Whenever the vehicle is raised on a hoist,
inspect the slip yoke boot for rips or holes. Replace if
required.
NOTE: All front driveshafts are balanced. If the vehicle
is to be undercoated, cover the driveshaft (4602) and
U-joints to prevent application of any undercoating
material.
The front axle driveshaft used on F-150, F-250, F-350
Part 4x4 and Bronco vehicles connects the power flow
from the transfer case to the front drive axle. It
Item Number Description incorporates two single Cardan universal joints
1 4635 Double Cardan Assembly (U-joints), one double Cardan on F-350, a driveshaft
2 4635 U-Joint with a splined stub shaft end, and a slip yoke boot with
3 4784 Driveshaft Center Yoke two slip yoke boot clamps, one large and one small.
4 4782 Driveshaft Centering Socket
Yoke
(Continued)

ALL RIGHTS RESERVED
05-01-7 Driveshaft 05-01-7
Front Drlveshaft, F-1SQ-250 4x4 and Bronco 4x4
UNIVERSAL JOINT
SLIP YOKE BOOT
4421
DRIVESHAFT
SLIP YOKE
FRONT YOKE 4841
(TO FRONT (TO TRANSFER
DRIVE AXLE) DRIVESHAFT CASE)
7A195 E&&8O-G
Front Drlveshaft, F-350 4x4 NOTE: Driveshafts and coupling shafts are balanced;
therefore, if the vehicle is being undercoated, the
..--------...o(AJ---------~ shafts and all open spline areas must be covered to
prevent undercoating material from getting on the
shafts.
Part
Item Number Description ASSEMBLED VIEW
1 - Rear Double Cardan (to
Automatic Transmission)
2 4602 Driveshaft
3 4421 Universal Joint Slip Yoke
Boot
4 4841 Driveshaft SItYoke
A - Dimension A:· 400- ~---®
970mm (38. 19 Inches)
C6 - 819mm (32.25 Inches)
M5HD (ZF) 7.5l and 7.3l-
832mm (32.75 Inches)
M5HD (ZF) 5.8l - 905.8mm
(35.66 Inches)
1330/1350 UNIVERSAL JOINTS E8740-B
Part
1 4A524 Bearing Strap Type
2 - Snap Ring Type
(Part of 4635)
3 4851 Companion (Universal Joint)
Flange
4 - Bearing Cup (Part of 4635)
5 - Needle Rollers
(Part of 4635)
6 - Grease Seal (Part of 4635)
7 - Trunnion (Part of 4635)
8 - Spider (Part of 4635)
9 4635 U-Joint Assembly
(Items 4, 5, 6, 7, 8)

ALL RIGHTS RESERVED
05-01-8 Driveshaft 05-01-B
Driveshaft Installation
Refer to Section 05-00. 1. To install the front driveshaft on F-350, align
index marks and position the single U-joint end of
the driveshaft to the front axle and install the
REMOVAL AND INSTALLATION U-bolts and nuts.
2. Position the U-joint to the transfer case with index
marks aligned and install the four bolts and
Driveshaft, Fror-t lockwashers.
Removal 3. Tighten the bolts at the transfer case to 28-33
1. To maintain driveshaft coupling shaft balance, N·m (21-25 Ib-ft), and the nuts at the front axle to
mark the driveshaft slip yoke (4841) in relation to 11-20 N·m (8-15Ib-ft).
the transfer case yoke for correct positioning 4. NOTE: When installing a new rear driveshaft,
during installation. align the factory-made yellow paint mark at the
2. Remove the nuts and U-bolts (bolts for F-350 at rear of the driveshaft tube with the factory-made
transfer case) that connect the rear driveshaft yellow paint mark on the outside diameter of the
slip yoke to the transfer case and the front yoke rear axle companion flange. If the paint marks are
to the front drive axle. not visible, and a vibration is present after
driveshaft installation refer to Driveshaft and
3. Remove the driveshaft from the vehicle. Wrap
Coupling Shaft Balancing in Section 05-00.
tape around the bearing caps to prevent the
bearings from falling off the U-joint spiders. To install the rear driveshaft on Bronco, position
the single U-joint end of the driveshaft to the rear
Installation axle with index marks aligned and install the
1. NOTE: If the driveshaft slip yoke and slip yoke U-bolts and nuts.
boot have been separated from the splined stub 5. Position the double Cardan joint to the transfer
shaft on the driveshaft, refer to disassembly and case with index marks aligned and install the four
assembly portion of this section. bolts and lockwashers.
Install the driveshaft so the marks on the 6. Tighten the bolts at the transfer case to 28-33
driveshaft slip yoke and transfer case yoke are in N·m (21-25 Ib-ft) and the nuts at the rear axle to
alignment. 11-20 N·m (8-15Ib-ft).
2. Install the nuts and U-bolts that retain the
driveshaft slip yoke to the transfer case yoke.
lighten nuts to 11-20 N·m (8-15Ib-ft). On F-350
tighten bolts to 28-33 N·m (21-25 Ib-ft).
3. Install the nuts and U-bolts that retain the front
driveshaft and coupling shaft yoke to the front
drive axle. lighten nuts to 11-20 N·m (8-15 Ib-ft).
With Double Cardan U-Joint
Removal
1. To remove the rear driveshaft (4602) on Bronco,
index mark the driveshaft in relation to the
transfer case and rear axle companion flange.
Disconnect the double Cardan U-joint from the
flange at the transfer case and the single U-joint
from the flange at the rear axle (4001). Wrap
tape around the bearing caps to prevent the
bearings from falling off the U-joint spiders.
Remove the driveshaft.
2. To remove the front driveshaft on F-350, index
mark the driveshaft in relation to the transfer
case and front axle universal joint flange.
Disconnect the double Cardan joint from the
flange at the transfer case and the single U-joint
from the flange at the front axle. Remove the Part
driveshaft. Wrap tape around the bearing caps Item Number Description
(front) to prevent the bearings from falling off the 1 4635 Double Cardan Assembly
U-joint spiders. 2 4635 U-Joint Assembly
3 4784 Driveshaft Center Yoke
4 4782 Driveshaft Centering Socket
Yoke
(Continued)
ALL RIGHTS RESERVED
05-01-9 Driveshaft 05-01-9
Part
5 - Centering Spring
(Part of 4635)
6 78214 Transfer Case Yoke (Flange)
Driveshaft, Rear
One-Piece
Removal
Raise vehicle and install safety stands.
1. NOTE: On four-wheel drive vehicles equipped
with a slip between center driveshaft, disconnect
the driveshaft (4602) at the transfer case during
removal.
To maintain driveline balance, if the yellow
alignment marks are not visible, mark the
relationship of the driveshaft flange yoke (4866)
and the rear axle companion flange so they may
be reinstalled in their original positions.
2. Circular rear axle companion flange:
E6118-B
Remove the bolts retaining the driveshaft flange
yoke to the rear axle companion flange and 2. Lubricate the slip yoke spline with Premium
disconnect the driveshaft from the rear axle Long-Life Grease XG-1-C or -K or equivalent
(400 1). Lower the driveshaft and slide the meeting Ford specification ESA-M1C75-B.
driveshaft rearward off the transmission output Remove the tool from the extension housing.
shaft. Install an appropriate plug in the extension Inspect extension housing seal for damage.
housing (7A039) to prevent fluid loss. Replace if necessary. Install the driveshaft slip
3. Half-round rear axle companion (universal joint) yoke (4841) on the transmission output shaft. Do
flange: not allow the driveshaft slip yoke to bottom on the
output transmission shaft with excessive force.
Remove the nuts retaining the driveshaft
universal joint U-bolt to the rear axle companion 3. Install the driveshaft so that the index marks
flange or bolts and straps. Disconnect the U-joint made before removal are aligned or the yellow
from the rear axle companion flange, being mark (if visible) on the driveshaft tube (light side)
careful not to drop the U-joint bearing cups. Wrap is in line with the yellow mark on the rear axle
tape around the U-joint to retain the bearing cups. companion flange high side runout. This prevents
Slide the driveshaft rearward off the vibration which occurs when the balance of the
transmission output shaft. Install an appropriate shaft and runout of the axle companion flange
plug in the extension housing to prevent fluid loss. become additive instead of neutralizing. If a
vibration exists, the driveshaft should be
Installation disconnected from the rear axle, rotated 180
When installing a new driveshaft, align the degrees and reinstalled.
factory-made yellow paint mark at the rear of the 4. On half-round rear axle companion (universal
driveshaft tube with the factory-made yellow paint joint) flange applications, install the U-bolts and
mark on the outside diameter of the rear axle nuts that attach the U-joint to the rear axle
companion flange. If paint marks are not visible and companion flange. If equipped with straps and
vibration exists after installation, refer to Driveshaft bolts, install and tighten bolts to specifications.
and Coupling Shaft Balancing in Section 05-00. Refer to Specifications at the end of this section.
1. If the lugs on the half-round rear axle companion On circular rear axle companion flange
flange are shaved or distorted so the bearings applications, install the bolts retaining the
slide, replace the rear axle companion flange. driveshaft flange yoke to the circular rear axle
companion flange. TIghten to 95-129 N·m (70-95
Ib-ft).
5. Remove stands and lower vehicle.
6. Road test vehicle

ALL RIGHTS RESERVED
05-01-10 Driveshaft 05-01-10
Driveshaft/Coupling Shaft, Two-Piece (Except 1. Using a brush, coat all surfaces of the coupling
F-Super Duty, Commercial Chassis and shaft front slip yoke splines with Premium
Motorhome Chassis) Long-Life Grease XG-1-C or -K or equivalent
meeting Ford specification. Remove the tool
To maintain driveline balance, mark the relationship of preventing leakage from the extension housing
the rear driveshaft yoke and the rear axle companion (driveshaft slip yoke applications only). Install the
flange before disassembly. front yoke of the coupling shaft on the output
Removal shaft. Do not allow the driveshaft slip yoke to
bottom on the output shaft with excessive force.
1. Raise the vehicle and install safety stands.
2. Secure the center bearing support bracket to the
2. Disconnect the driveshaft from the rear axle frame crossmember with the center support
companion flange and disconnect the driveshaft attaching bolts and spacers. lighten the bolts to
slip yoke from the coupling shaft yoke. Wrap tape 40-64 N·m (30-47Ib-ft).
around the loose bearing caps to prevent the
bearings from falling off the transaxle universal 3. Apply a coating of Premium Long-Life Grease
joint spiders. XG-1-C or -K or equivalent meeting Ford
specification ESA-M 1C75-B to entire splined stub
3. Remove the two center bearing support (coupling shaft end of the coupling shaft prior to the
shaft)-to-frame crossmember attaching bolts assembling of the driveshaft and the driveshaft
noting exact location of the support. Remove the slip yoke.
coupling shaft assembly. Wrap tape around the
loose bearing caps. Install the appropriate tool in 4. Using a clean long handle (stencil type) brush
the extension housing to prevent leaking. apply Premium Long-Life Grease XG-1-C or -K or
4. Clean the male splines of the coupling shaft and ESA-M 1C75-B, spread evenly on all the female
driveshaft with a wire brush and a suitable splines of the driveshaft slip yoke.
solvent. Remove all hardened grease deposits,
dirt or rust. Do not remove the blue plastic 5. Assemble the driveshaft slip yoke to the coupling
coating from male splines. Inspect for worn or shaft.
galled splines. Remove any nicks, gouges or 6. Connect the rear U-joint of the driveshaft to the
burrs from the driveshaft using a file or emery rear axle companion flange and tighten the U-bolt
cloth. nuts or strap bolts to specification. Refer to
5. Inspect the driveshaft slip yoke seal for rips, Specifications at the end of this section.
holes or deformation. Replace if necessary. 7. NOTE: To ensure complete lubrication of the
6. Using a suitable cleaning fluid, clean all dirt from driveshaft slip yoke splines, temporarily plug the
the driveshaft slip yoke internal splines and the vent hole in the "welch" type plug located at the
driveshaft slip yoke. Carefully inspect the yoke end of the driveshaft slip yoke while
driveshaft slip yoke splines for wear or evidence applying grease through the zerk fitting.
of twisting. Check the operation of the driveshaft Using a hand type grease gun, lubricate the
slip yoke. driveshaft slip yoke through the zerk fitting with
7. Wash all parts except the sealed center bearing Premium Long-Life Grease XG-1-C or -K or
and rubber insulator in suitable cleaning fluid. Do equivalent meeting Ford specification
not immerse the sealed bearing in the ESA-M1C75-B.
cleaning fluid. Wipe the bearing and rubber 8. Remove safety stands and lower vehicle.
insulator clean with a cloth dampened in cleaning
fluid. 9. Road test vehicle.
8. Check the driveshaft center bearing for wear or Driveshaft, Two- or Three-Piece, F-Super Duty
rough action by rotating the inner race while Commercial Chassis and Motorhome Chassis
holding the outer race. If any wear or roughness Vehicles
is evident, replace the driveshaft center bearing
support (4800). Removal
9. Examine the rubber insulator for evidence of 1. Disconnect the driveshaft from the flange at the
hardening, cracking, or deterioration. Replace if rear axle.
damaged in any way. 2. Slide the driveshaft off the coupling shaft splines.
Installation 3. Working from the driveshaft center bearing
support nearest to the rear of the vehicle, remove
When installing a new driveshaft, align the the two center bearing bracket to support plate
factory-made yellow paint mark at the rear of the bolts and support the driveshaft center bearing
driveshaft tube with the factory-made yellow paint bracket (4A499).
mark on the outside diameter of the rear axle
companion flange. If paint marks are not visible and a 4. Remove the forward joint from its mating yoke
vibration exists after installation, refer to Driveshaft and remove driveshaft. As the driveshafts are
and Coupling Shaft Balancing in Section 05-00. removed, wrap tape around the loose bearing
cups.
ALL RIGHTS RESERVED
05·01·11 Driveshaft 05-01-11
5. Repeat two previous steps until last shaft has Driveshaft Installation, Two-Piece
been removed.
6. Thoroughly clean old grease and dirt from the
driveshaft splines and then check the splines for
wear, warpage and cracks. If the shaft is worn,
warped, or cracked, replace it.
7. Using a suitable cleaning fluid, clean all dirt from
the driveshaft slip yoke, driveshaft slip yoke
splines, and shaft splines.
Do not clean the plastic coating on the male VIEW OF AXLE AND
splines with a wire brush. Do not remove the TRANSMISSION ATTACHMENT
plastic coating from the male splines.
8. Carefully inspect the driveshaft slip yoke splines
for wear or evidence of twisting. Check the
clearance between the driveshaft slip yoke
splines and the shaft splines.
9. Wash all parts except the driveshaft center
bearing support in suitable cleaning fluid. Do not
immerse the sealed bearing in cleaning fluid.
Wipe the bearing and rubber insulator clean with
a cloth dampened with cleaning fluid.
10. Check the bearing for wear or rough action by
~SUPERDUTYCOMMER~LAND
rotating the inner race while holding the outer MOTORHOME STRIPPED CHASSIS
race. If wear or roughness is evident, replace the
bearing.
11. Examine the rubber insulator for evidence of
hardening, cracking, or deterioration. Replace it if
it is damaged in any way.
12. Grease retainers and slingers are serviced only
as part of the driveshaft center bearing support.
Installation
1. Connect the front joint of the coupling shaft to the INSTALL "IN PHASE" AS SHOWN
yoke on the transmission. Tighten the bolts to
specification. Part
2. Support the driveshaft and install the center Item Number Description
bearing bracket to support plate bolts and nuts. 1 390880-5 Bolt
Tighten the bolts to 68-95 N·m (50-70 Ib-ft). Make
2 4A254 Driveshaft Universal Joint
sure that the center bearing is not twisted in the Spider Retainer
support plate.
3 4831 Support Plate
3. If working on a vehicle with more than one 4 58654-5 Bolt and Nut
coupling shaft, connect the rear shaft to the 5 4602 Driveshaft
forward one, then install the remaining driveshaft 6 - Axle End (Part of 4602)
center bearing support. All splines should be
lubricated with High Temperature Grease
7 - Transmission End
(Part of 4602)
E43Z-19590-A or equivalent meeting Ford
specification ESP-M 1C207-A.
(23-30 Lb-Ft)
4. Connect the rear U-joints to the rear axle flange B - Tighten to 68-95 N·m
and tighten the bolts to specification found at the (50-70 Lb-Ft)
end of this section. Make sure all driveshaft and C - 158-lnch and 178-lnch
coupling shaft yokes are properly in phase. Wheelbase
ALL RIGHTS RESERVED
05·01·12 Driveshaft 05·01·1~
~ Driveshaft Installation, Three-Piece

208- AND 22&-INCH WHEELBASE
F-8UPEA DUTY MOTORHOME CHASSIS VEHICLES
.,
FRONT OF VEHICLE
VIEW A
E8233-D
Part Part
1 4831 Support Plate A - Tighten to 40-64 N·m
2 4602 Driveshaft (30-47 Lb-Ft)
3 - Axle End (Part of 4602) B - 208-lnch Wheelbase
4 - Transmission End C - See Chart for Holes to Mount
(Part of 4602) to Crossmember
5 N630088 Washer 0 - Align with Holes 2 and 4
6 N605921 Bolt E - Numbers Are Stamped into
Part
7 - Nut
F - Align with Holes 1 and 3
8 5019 Frame Crossmember
(Continued)
Driveshaft, Single Cardan Universal Joint Disassembly

1. CAUTION: Under no circumstances is the
SPECIAL SERVICE TOOL(S) REQUIRED driveshaft to be clamped in the jaws of a vice
Description Tool Number or similar holding fixture. Denting or
localized fracture of the tube may result,
U-Joint Tool T74P-4635-C which may cause driveshaft and coupling
shaft failure during vehicle operation.
Place the driveshaft on a suitable workbench,
being careful not to damage the tube.
ALL RIGHTS RESERVED
05-01-13 Driv8shaft 05-01-13
2. NOTE: If components are not marked and

therefore installed incorrectly, driveline imbalance
may occur.
Prior to disassembly, mark the positions of the
driveshaft components relative to the driveshaft
tube. All components must be reassembled in the
same relationship to maintain proper balance.
3. Clamp U-Joint Tool T74P-4635-C in vise.
E9239-A
4. Remove the snap rings that retain the bearing

cups.
6. Reposition the driveshaft slip yoke in U-Joint Tool

180 degrees to press on the spider and remove
'll\l~""'-- SNAP the remaining bearing cup from the opposite side.
RING
7. Remove driveshaft slip yoke from the spider.
8. Remove the remaining bearing cups, spiders and
driveshaft flange yoke (4866) from the driveshaft
(4602) in the same manner.
9. Clean all foreign matter from the yoke area at
each end of the driveshaft.
Assembly
Universal joint kits are to be installed as complete
E9091·A
assemblies only. Do not mix components from other
5. Position the driveshaft slip yoke (4841) in the universal joints.
U-Joint Tool and press out bearing. If bearing cup 1. Start a new bearing cup into the driveshaft yoke.
cannot be pressed all the way out of the
driveshaft slip yoke, remove it with vise grip or
channel lock pliers.
ALL RIGHTS RESERVED
05-01-14 Driveshaft 05-01-14
2. Position the new spider in the driveshaft yoke and 8. Check U-joints for freedom of movement. The
press the bearing cup 6.3mm (1 /4 inch) below effort required for movement should not exceed 4
the yoke surface using the U-Joint Tool. N·m (35 Ib-in) when measured with a spring scale.
If binding has resulted from misalignment during
assembly, a sharp rap on the yokes with a brass
or plastic hammer will seat bearing needles. Take
care to support the shaft end and do not strike
the bearings during this procedure. Make
sure U-joints rotate easily without binding before
installing driveshaft.
ROTATE
SLIP YOKE
3. Remove driveshaft from U-Joint Tool and install a

new snap ring.
4. Start a new bearing cup into the opposite side of E7590-A
the yoke. Check needles for proper position.
5. Position driveshaft in U-Joint Tool and press on
the bearing cup until the opposite bearing cup
contacts the snap ring.
6. NOTE: Assemble universal joint using the yellow
snap rings supplied in the kit. If difficulty is
encountered with yellow snap rings, install the
black snap rings supplied in the kit.
Remove the driveshaft from tool and install a new
snap ring. Check snap ring for proper seating.
E9104-8
SNAP
RING 9. Lubricate the universal joints (if equipped with
grease fittings) with Premium Long-Life Grease
Driveshaft, Double Cardan Universal Joint

E7589·A SPECIAL SERVICE TOOL(S) REQUIRED
7. Install the remaining new bearing cups, spider, Description Tool Number
driveshaft slip yoke, driveshaft flange yoke and
U-Joint Tool T74P-4635C
snap rings in the same manner.
ALL RIGHTS RESERVED
05·01·15 Driveshaft 05·01·15
Disassembly 6. Lift the two bearing cups from the spider.

driveshaft to be clamped in the jaws of a vice
or similar holding fixture. Denting or
localized fracture of the tube may result,
which may cause driveshaft failure during
vehicle operation.
Place the driveshaft (4602) on a suitable
workbench being careful not to damage the tube.
2. Mark the positions of the spiders, the driveshaft
center yoke (4784), and the driveshaft centering
socket yoke (4782) as related to the stud yoke
which is welded to the front of the driveshaft.
3. Remove the snap rings that secure the bearings
in the front of the driveshaft center yoke.
4. Position the U-Joint Tool T74P-4635-C as shown.
Tighten the tool clockwise until the bearing
protrudes approximately 9.525mm (3/8 inch) out
of the yoke.
7. Reposition the tool on the driveshaft center yoke
and move the remaining bearing in the opposite
direction so that it protrudes approximately
9.525mm (3/8 inch) out of the driveshaft center
yoke.
8. Clamp the bearing in a vise. Tap on the driveshaft
center yoke to free it from the bearing.
9. Remove the spider from the driveshaft center
yoke.
10. Pull the driveshaft centering socket yoke off the
center stud. Remove the rubber seal from the
centering ball stud.
CENTER
STUD
5. Clamp the bearing in a vise and tap on the
driveshaft center yoke to free it from the bearing.
DRIVESHAFT
CENTERING
SOCKET
YOKE
4782
E2334-E
11. Remove the snap rings from the driveshaft center
yoke and from the driveshaft yoke.
E2332-D
ALL RIGHTS RESERVED
05-01-16 Driveshaft 05-01-16
12. Position the U-joint tool on the driveshaft yoke Assembly

and press the bearing outward until the inside of 1. NOTE: Universal joint kits are to be installed as
the driveshaft center yoke almost contacts the oil complete assemblies only. Do not mix any
slinger at the front of the driveshaft yoke. components from other universal joint kits. .
To assemble the double Cardan joints, position
the spider in the driveshaft yoke. Make sure the
spider bosses (or lubrication plugs on kits) will be
in the same position as originally installed. Press
in the bearing using U-Joint Tool T74P-4635-C.
Install the snap rings.
2. Pack the socket relief and the ball with the
ESA-M 1C75-B, then position the driveshaft
center yoke over the spider ends and press in the
bearing. Install the snap rings.
3. Install a new seal on the centering ball stud.
E2335-F Position the driveshaft centering socket yoke on
the stud.
Pressing beyond this point can distort the oil 4. Place the front spider in the driveshaft center
slinger. The arrow in the following illustration yoke. Make sure the spider bosses are properly
shows the interference point. positioned.
5. With the spider loosely positioned on driveshaft
center yoke, proceed to seat the first pair of
SLINGER bearings into the driveshaft centering socket
RING
yoke, then press the second pair into the
driveshaft center yoke. Install the snap rings.
6. Apply pressure on the driveshaft centering
socket yoke and install the remaining bearing
cup.
7. Lubricate the universal joint (if equipped with
grease fittings) with Premium Long-Life Grease
Center Bearing
Disassembly
.driveshaft to be clamped in the Jaws of a vise
or similar holding fixture. Denting or
E233&-D localized fracture of the tube may result,
which may cause driveshaft failure.
13. Clamp the exposed end of the bearing in a vise
and drive on the driveshaft center yoke with a Place the coupling shaft / center bearing on a
soft-faced hammer to free it from the bearing. suitable workbench, being careful not to damage
the tube.
14. Reposition the tool and press on the spider to
remove the opposite bearing. 2. Separate slip yoke from coupling shaft (if
attached).
15. Remove the driveshaft center yoke from the
spider. 3. Remove driveshaft center bearing bracket
(4A499) and retainer.
16. Remove the spider from the driveshaft yoke in the
same manner. . 4. Remove the rubber insulator.
17. Clean all serviceable parts in cleaning solvent. If 5. Press (using a suitable press) driveshaft center
using a repair kit, install all of the parts supplied in bearing support (4800) and bearing retainer off
the kit. If the driveshaft is damaged, replace the the coupling shaft.
complete shaft to be assured of a balanced 6. Press the dust slinger off the coupling shaft.
assembly.

ALL RIGHTS RESERVED
05-01-17 Driveshaft 05-01-17
Assembly 2. Install dust slinger. Install driveshaft center

1. Replace with Center Bearing Assembly Kit bearing bracket in the rubber insulator and press
D9TZ-4800-A or equivalent in all cases except the bearing on the shaft with the turned-in lip
E4TZ-4800-A for F-250 HD, F-350, and F-Super toward the dust slinger (forward). The support
Duty Chassis Cab with the ZF transmission. bracket must be installed with the deep flange
rearward.
Slip Between Center Driveshaft
FRONT DRlVE8HAFT - A88EMBLED
FRONT DRIVE8HAFT - EXPLODED VIEW

E&I81-C
Part Part
1 4635 Universal Joint Kit 7 4421 Slip Yoke Boot
2 - Bearing (Part of 4635) 8 4841 Driveshaft Slip Yoke
3 - Snap Ring (Part of 4635) 9 - Boot Groove (Part of 4841)
4 - Seal (Part of 4635) 10 4K227 Large Clamp
5 - Spider (Part of 4635) 11 4K227 Small Clamp
6 - Splined Stub Shaft 12 4602 Driveshaft
(Part of 4602) 13 - Front Driveshaft Yoke
(Continued) (Part of 4602)

Keystone Clamp Pliers T63P-9171-A
ALL RIGHTS RESERVED
05-01-18 Driveshaft 05~01-18
Disassembly 2. In~tall a small drive~haft slip yoke boot clamp and

1. With the front driveshaft on a bench, cut the cnmp the clamp uSing Keystone Clamp Pliers
driveshaft slip yoke boot clamps (4K227) with T63P-9171-A.
sidecutters. Remove and discard the clamps.
3. Pull the slip yoke boot towards the driveshaft and

coat the stub shaft splines with Premium
Long-Life Grease XG-1-C or -K or equivalent
meeting Ford specification ESA-M1C75-B.
4. Fill the slip yoke boot with approximately 10
EMI2-1A grams of Premium Long-Life Grease XG-1-C or -K
2. Separate the driveshaft slip yoke (4841) from the or equivalent meeting Ford specification
ESA-M1C75-B.
splined stub shaft on the driveshaft.
5. Slide the large driveshaft slip yoke boot clamp
3. Remove the slip yoke boot. Inspect the slip yoke
onto the barrel of the driveshaft slip yoke.
boot for rips or holes and replace if required.
6. Align the blind splines on the splined stub shaft
4. If during inspection, the driveshaft and coupling
and in the driveshaft slip yoke. Push the
shaft boot is found to be cracked or split, the
driveshaft slip yoke onto the stub shaft.
grease should be checked for contamination.
Check the lubricant by rubbing between two
fingers. Any gritty feeling indicates a
contaminated driveshaft slip yoke and stub shaft.
If driveshaft (4602) is operating satisfactorily and
the grease does not appear to be contaminated,
add grease as described in the assembly portion
of this procedure and replace the slip yoke boot.
If the grease appears contaminated, disassemble
the driveshaft and inspect the stub shaft and
driveshaft slip yoke for wear.
5. If required, remove and install the U-joints as
Assembly
1. Install the slip yoke boot with the small diameter
side facing the splined stub shaft on the stub
shaft. Push the slip yoke boot as far as it will
travel on the stub shaft. BLIND SPLINES EISI88-1A
LARGE
DIAMETER 7. Remove all excess grease from the slip yoke
boot and driveshaft slip yoke surfaces. Position
the slip yoke boot over the driveshaft slip yoke
boot groove.
SMALL
DIAMETER
E6&lM-1A

ALL RIGHTS RESERVED
05-01-19 Driveshaft 05-01-19
DISASSEMBLY AND ASSEMBLY (Continued) ADJUSTMENTS
8. Move the driveshaft slip yoke in or out in order to For adjustment procedures including driveshaft and
obtain the distance of 10 inches between stud coupling shaft runout and balance, refer to Component
shaft weld to the centerline of the driveshaft slip Tests or Adjustments in Section 05-00.
yoke U-joint.
Driveshaft Alignment
Before adjusting components for correct driveshaft
and coupling shaft alignment, be sure to check the
following.
1. Alignment of drivelines must be accomplished
with the empty vehicle sitting on a hard level
E8744-A
surface.
2. All angle measurements must be made on a
9. Before installing the new large slip yoke boot surface or the component which is either parallel
clamp, make sure that any air pressure which to or perpendicular to the center line of the
may have built up in the slip yoke boot is relieved. component being measured.
Carefully insert a screwdriver between the slip
3. Angle measurements must be made with either a
yoke boot and the driveshaft slip yoke and allow
spirit level or an inclinometer. Angle values given
the trapped air to escape ("burp") from the slip
in Section 05-00 are nominal values with a
yoke boot. THE AIR MUST BE RELEASED ONLY
tolerance of ± 1 /4 degree.
AFTER THE DRIVESHAFT IS SET AT THE
SPECIFIED LENGTH.
Driveline Support Plate, Adjustable

F-Super Duty Commercial Chassis
An adjustable driveline support plate is used. Although
it can be mounted in anyone of several positions, only
one position is correct for a specific application. The
correct position can be determined from the following
illustration.
E5&87·B
10. Position the new large driveshaft slip yoke boot

clamp over the slip yoke boot and groove in the
driveshaft slip yoke. Crimp the driveshaft slip
yoke boot clamp with Keystone Clamp Pliers
T63P-9171-A.

ALL RIGHTS RESERVED
05-01-20 Driveshaft 05-01-20
~ Adjustable Driveline Support Plate Position

Part
~
FRONT OF VEHICLE 3 5028 Frame Crossmember
A - Legs of Support Plate Must
Always Face Front of Vehicle
As Shown
B - 48.5mm (1.91 Inch) with
Main and Auxiliary Springs
- 158-lnch Wheelbase
C - 22.4mm (0.88 Inch) with
Main and Auxiliary Springs
- 178-lnch Wheelbase
D - Align with Holes 2 and 4
E - Numbers Are Stamped into
Part
F - Align with Holes 1 and 3
WITH MAIN AND AUXILIARY SPRINGS F-Super Duty Motorhome Chassis

An adjustable driveline support plate is used. Although
it can be mounted in anyone of several positions, only
one position is correct for a specific application. The
correct position can be determined from the following
chart and illustration.
SUPPORT PLATE POSITION

Use Mount
Support Wheelbase Holes
Forward 208-lnch No.3
Forward 228-lnch NO.1
Rearward 208-lnch No.4
Rearward 228-lnch No.5
USE NO.1 HOLES TO MOUNT TO CROSSMEMBER Single 178-lnch No.2
FOR 158-1NCH WHEELBASE
Single 190-lnch NO.2
USE NO.3 HOLES TO MOUNT TO CROSSMEMBER
FOR 178-INCH WHEELBASE
E8093-D
Part
1 4831 Support Plate
2 5015 Frame Side Rail
(Continued)
ALL RIGHTS RESERVED
05-01-21 Driveshaft 05-01-21
Adjustable Driveline Support Plate Position
-.
FRONT OF VEHICLE
USING THE COUPLING SHAFT SUPPORT PlATE

4831 SHOWN WITH THE ATIACHING PARTS
INSTALLED IN THE SPECIFIED HOLES, THE BOTTOM
OF THE SUPPORT PLATE TO THE BOTTOM OF THE
FRAME MEASURES AS NOTED ABOVE
E8742-E
Part Part
1 - Frame Crossmember F - 10.4mm (0.41 Inch) 208-lnch
(Part of 5005) Wheelbase Rearward
2 4831 Support Plate Support
3 - Frame Side Rail G - 35.6mm (1.40 Inch) 178- and
(Part of 5005) 190-lnch Wheelbase Single
Support
A - Align with Holes 2 and 4
H - 48.5mm (1.91 Inch) 228-lnch
B - Numbers Are Stamped into Wheelbase Forward Support
Part
J - 2.5mm (0.10 Inch) 228-lnch
C - Align with Holes 1 and 3 Wheelbase Rearward
0 - Legs of Support Plate Must Support (Support Plate
Always Face Front of Vehicle Mounting Surface Below
As Shown Bottom of Frame)
E - 74.4mm (2.93 Inch) 208-lnch
Wheelbase Forward Support
(Continued)
SPECIFICATIONS

Description N·m Lb-Ft Description N·m Lb-Ft
Bolt Yoke to Coupling Shaft 5/8-18 201-222 148-164 Nut-U-Joints - Driveshaft 24-35 18-26
(Dana) (Dana) Universal Joint Bolt 3/8-18
Bolt Yoke to Coupling Shaft 3/4-16 238-325 175-240 Nut-U-Joints - Driveshaft 41-54 30-40
Universal Joint Bolt 7 / 16-20
Bolt Yoke to Coupling Shaft 7/8-14 339-406 250-300
Coupling Shaft Center Bearing 68-95 50-70
Bolt Yoke to Coupling Shaft 1-20 216 160
Bracket-to-Support 7 / 16-20
Nut-U-Joints - Driveshaft 11-20 8-15
Bolt - Driveshaft U-Joint to Rear 123-149 91-110
Universal Joint Bolt 5/ 16-18
Yoke 1/2-20
(Continued)
(Continued)
ALL RIGHTS RESERVED
05-01-22 Driveshaft 05-01-22
SPECIFICATIONS (Continued) SPECIAL SERVICE TOOLS/EQUIPMENT
TORQUE SPECIFICATIONS (Cont'd) SPECIAL SERVICE TOOLS REQUIRED

Description N·m Lb-Ft Tool Number /
Bolt and Nut - U~Joint Adapter to 82~94 60~70
Rear Axle 1/2-20 T7 4P~4635~C
U-Joint Tool
~
Bolt - Circular Rear Axle 95~129 70~95
Companion Flange to Driveshaft
Flange Yoke M 12~ 1.25 x 27
Double Cardan 28~38 20-28 T74'....31-C
Driveshaft~to~Transfer Case Bolts
T63P~9171 ~A
<
5/16~24
Keystone Clamp Pliers
Driveshaft~to~Frontand Rear Axle 11~20 8-15
U~Bolt Nuts 5 / 16~ 18
Center Support 40~64 30~47

TaP·ln 71·A
Bracket~to~Crossmember
1995 F·150, F·250, F·350, Bronco, F~Super Duty Powertrain, Drivetrain July 1994
ALL RIGHTS RESERVED
05-02A-1 Axle, 10.25-lnch Ring Gear 05-02A-1
SECTION OS-02A Axle, 10.2S-lnch Ring Gear

VEHICLE APPLICATION ......•.•.......................•.•.•......OS-02A-1 REMOVAL AND INSTALLATION (Cont'd.)
DESCRIPTION AND OPERATION Sensor Indicator, Anti-Lock Brake OS-02A-26
Axle OS-02A-1 DISASSEMBLY AND ASSEMBLY
Brakes, Anti-Lock, Rear ...................•...................OS-02A-6 Differential Case OS-02A-26
DIAGNOSIS AND TESTING CLEANING AND INSPECTION
Axle ...................................•................•...............OS-02A-6 Inspection After Disassembly OS-02A-28
REMOVAL AND INSTALLATION Bearing Cups OS-02A-28
Axle Housing .....................•........•...............•....•.OS-02A-24 Carrier Housing •........................•....•........••.•...OS-02A-29
Axle Shaft, Semi-Floating Axle ....•........................OS-02A-7 Companion Flange ............................•............OS-02A-28
Differential Case and Drive Pinion .......•.......•......OS-02A-10 Cone and Roller Assemblies .•.........................OS-02A-28
Differential Runout Check...•.......•................•.....OS-02A-13 Differential Case ....•.......................................OS-02A-29
Drive Pinion Shim Selection OS-02A-1S Gears OS-02A-29
Oil Seal and Wheel Bearing, Semi-Floating Inspection Before Disassembly OS-02A-27
Axle ..........................................•.....................•OS-02A-9 SPECIFICATIONS ~ OS-02A-29
Pinion Bearing Cups, Front and Rear ...........•......OS-02A-14 SPECIAL SERVICE TOOLS/EQUIPMENT OS-02A-30
VEHICLE APPLICATION
F-250 Light Duty (Semi-Float), F-250 HD and F-350
(Full Float)
Axle Wheel end service procedures for the semi-floating

The Ford Truck Integral Carrier rear axle assembly is axle are included in this section. For full-floating rear
an integral type housing, hypoid gear design with the hub (1109) service procedures, refer to Section
centerline of the pinion set below the centerline of the 05-028.
ring gear. The rear axle drive pinion receives its power from the
The hypoid ring gear and pinion consists of a engine through the transmission and driveshaft
10.25-inch diameter ring gear and an overhung drive (4602). The pinion gear rotates the differential case
pinion. The pinion is positioned by selected pinion through engagement with the ring gear, which is bolted
shims and supported by two cone and roller bearings. to the case outer flange.
Pinion bearing preload is adjusted by the pinion nut and Inside the case, two pinion gears are mounted on the
a collapsible spacer. differential pinion shaft which is pinned (with lock bolt)
The housing consists of a cast center section with two to the case. These pinion gears are engaged with the
steel tubes and a stamped rear cover. The cover uses differential side gears (4236), to which the axle shafts
a silicone sealant as a gasket. (4234) are splined. Therefore, as the differential case
turns, it rotates the axle shafts and rear wheels. When
The differential case (4204) is a one-piece design with it is necessary for one wheel and axle shaft to rotate
two openings to allow for assembly of the internal faster than the other, the faster turning differential side
components and lubricant flow. The differential pinion gear causes the pinions to roll on the slower turning
shaft (4211) is retained with a threaded bolt. The differential side gear to allow differential action
differential case is mounted in the carrier between two between the two axle shafts.
cone and roller bearings and is positioned by selected
shims. The bearings are retained in the carrier by
removable bearing retaining caps.
ALL RIGHTS RESERVED
Integral Carrier, Rear Axle Assembly
E8109·E
Part Part
1 4851 Rear Axle Companion Flange 6 4209 Ring Gear
2 4621 Front Bearing Cone and 7 4067 Shim
Roller 8 4221 Differential Bearing
3 4B409 Anti-Lock Ring 9 4209 Drive Pinion
4 4236 Differential Side Gear 10 4630 Drive Pinion Cone and Roller
5 4204 Differential Case 11 4676 Pinion Seal
(Continued)

ALL RIGHTS RESERVED
Integral Carrier, Rear Axle Assembly, Disassembled View, Semi-Floating Axle, Typical

ALL RIGHTS RESERVED
Part Part
1 - Ratio Tag (Not Serviced) 20 4628 Rear Pinion Bearing Cup
2 390864-S2 Cover Screw 21 46157-S Bearing Cap Bolt
3 4033 Cover 22 2C190 Rear Brake Anti-Lock
4 4228 Thrust Washer Sensor
5 4236 Differential Side Gear 23 4A001 Axle Vent Assembly
6 4241 Differential Pinion Shaft Lock 24 4010 Axle Housing
Bolt 25 390943-S 100 Filler Plug
7 4N237 U-Washer (Semi-Float Only) 26 4662 Collapsible Spacer
8 4230 Thrust Washer 27 4670 Oil Slinger
9 4215 Pinion Gear 28 4851 Rear Axle Companion Flange
10 4211 Differential Pinion Shaft 29 4851 Pinion Nut
11 4221 Differential Bearing 30 4676 Pinion Seal
12 4067 Shim 31 4621 Front Bearing Cone and
13 4222 Differential Bearing Cup Roller
14 43114-S100 Ring Gear Bolt 32 4616 Front Pinion Bearing Cup
15 4204 Differential Case 33 4234 Axle Shaft
16 4B409 Anti-Lock Speed Sensor 34 1225 Rear Wheel Bearing
Ring 35 1177 Inner Wheel Bearing Oil Seal
17 4209 Ring Gear and Pinion 36 390540-S Wheel Bolt
18 4663 Pinion Shim 37 - Spring Push-On Nut
19 4630 Drive Pinion Bearing Cone (Not Serviced)
and Roller 38 391220-S56 Brake Backing Plate Nut
(Continued) 39 2248 Bolt, Brake Backing Plate
ALL RIGHTS RESERVED
Integral Carrier, Rear Axle Assembly, Disassembled View, Full-Floating Axle, Typical
DUAL REAR WHEEL VEHICLES

SAME AS MAIN VIEW
EXCEPT AS SHOWN
E6472·F
ALL RIGHTS RESERVED
Part Part
1 4033 Axle Housing Cover 30 4234 Axle Shaft
2 - Ratio Tag (Not Serviced) 31 46053-S100 Bolt, Axle Shaft
3 390864-S2 Screw 32 390258-S O-Ring, Axle Shaft
4 4230 Differential Pinion Thrust 33 1116 Hub
Washer 34 390268-S Press Fit Stud
5 4215 Differential Pinion Gear 35 2200 Backing Plate and Brake
6 4211 Differential Pinion Shaft Shoe Assembly
7 4236 Differential Side Gear 36 1239 Outer Bearing Cup
8 4228 Differential Side Gear Thrust 37 1202 Bearing Cup
Washer 38 1244 Rear Wheel Bearing Inner
9 4221 Differential Bearing Cone and Roller
10 4067 Differential Bearing Shim 39 1177 Inner Wheel Bearing Oil Seal
11 4222 Differential Bearing Cup 40 - Keyway (Part of 4010
12 43114-S 100 Ring Gear Bolt Housing)
13 4204 Differential Case 41 - Spindle (Part of 4010
Housing)
14 4663 Drive Pinion Bearing
Adjustment Shim 42 4628 Rear Axle Pinion Bearing
Cup
15 46157-S Bearing Cap Bolt
43 4630 Differential Pinion Bearing
16 2L373 Rear Brake Anti-Lock
Sensor 44 4209 Differential Ring Gear and
Pinion
17 4A001 Axle Vent Assembly
45 4B409 Anti-Lock Speed Sensor
18 4010 Rear Axle Housing Ring
19 390943-S 100 Filler Plug Differential Pinion Shaft Lock
46 4241
20 4662 Differential Drive Pinion Pin
Collapsible Spacer 47 - Four Clearance Holes in
21 4670 Rear Axle Drive Pinion Shaft Drum for Wheel Pin and Hub
Oil Slinger (Part of 1126)
22 4851 Rear Axle Universal Joint 48 1107 Wheel Hub Bolts
Flange 49 - Two Wheel Pin Locating
23 4851 Pinion Nut Holes (Part of 1116)
24 4676 Rear Axle Drive Pinion Seal 50 1120 Wheel Lugnut
25 4621 Differential Pinion Bearing 51 - Locating Hole in Wheel
26 4616 Differential Drive Pinion (Part of 1001)
Bearing Cup 52 - Locating Hole in Wheel
27 1240 Outer Bearing (Part of 1001)
28 1A124 Hub Nut 53 305136-S7 Locating Pin in Wheel
29 1126 Brake Drum (Part of 1001)
(Continued)

Brakes, Anti-Lock, Rear
F-250, F-350 vehicles use the rear anti-lock braking Axle
system. The system is designed to automatically
reduce brake pressure when brake lockup is detected
during braking. The system features an anti-lock
speed sensor ring that is pressed on the differential
case (4204) behind the ring gear. If the anti-lock speed
sensor ring is removed, it must be discarded and
replaced with a new one. The anti-lock speed sensor
ring works in conjunction with the rear brake anti-lock
sensor retained in a bore at the top of the carrier and
fastened by one bolt. There is a space provided
between the ring gear and anti-lock speed sensor ring
for measuring the ring gear backface runout. For more
information on the Rear Anti-Lock Brake System, refer
to Section 06-09A.

ALL RIGHTS RESERVED
Axle Shaft, Semi-Floating Axle

Removal
1. NOTE: Refer to Section 05-028 for full-floating
axle shaft removal.
Clean all dirt from the area of carrier cover with a
wire brush or cloth.
DIFFERENTIAL
PINION SHAFT
421'
E4708-C
E5863-B
2. Place a drain pan under the axle and drain rear 4. NOTE: Use care not to lose or damage the rubber
axle lubricant by removing the housing cover. a-ring which is in the axle shaft groove under the
u-washer (4N237).
Push axle shafts (4234) inboard. Remove
U-washer from the button end of each axle shaft.
O-RING
E5864·B
3. Remove lock pin and differential pinion shaft

(4211).
U-WASHER
4N237
E4709-D

ALL RIGHTS RESERVED
OS-02A-8 Axle, 10.2S-lnch Ring Gear OS-02A-8
5. Remove axle shaft from the axle housing, being

careful not to damage the inner wheel bearing oil
seals (1177).
LOCK BOLT
4241
E4760-1B DIFFERENTIAL
PINION SHAFT
Installation 4211
1. Slide the axle shafts into place in the axle E4708-e
housing. Exercise care so that the splines or any CAUTION: Make sure machined surfaces on
4.
portion of the axle shafts do not damage the inner both cover and carrier are clean and free of
wheel bearing oil seals. Push the axle shafts oil before installing the new silicone sealant.
inboard (toward the center of the vehicle) enough
Inside of axle must be covered when
to allow installation of the U-washer. cleaning the machined surface to prevent
2. NOTE: A rubber a-ring is used to hold the contamination.
U-washer in position on the axle shaft. Be sure Clean the gasket mating surface of the rear axle
that the a-ring is in the groove at the button end carrier casting and cover.
of the axle shaft before installing the U-washer.
5. NOTE: Cover must be installed within 15 minutes
Install the U-washers on the button end of the axle of application of the silicone or new sealant must
shafts and push the shafts outboard so that the be applied.
shaft lock seats in the counterbore of the
differential side gear (4236). Apply a new continuous bead of Silicone Rubber
D6AZ-19562-AA or -BA or equivalent meeting
3. Position the drive pinion shaft through the case Ford specification ESB-M4G92-A or
and pinions, aligning the hole in the drive pinion ESE-M4G 195-A to the carrier casting face
shaft with the hole in the lock pin. Apply inboard of the cover bolt holes.
Threadlock and Sealer EOAZ-19554-AA or
WSK-M2G315-A5 (Type II) to the lock bolt
threads. Install lock pin and tighten to 20-40 N·m
(15-30 Ib-ft).
7
-1Iff' TO 3/16" WIDE
CONTINUOUS BEAD
OF SILICONE
RUBBER SEALANT
/
/ E471G-1B
L---------------------:-:19:-:9~5 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
05-02A-9 Axle, 10.2S-lnch Ring Gear 05-02A-9
6. Install cover and tighten cover bolts to 38-52 N·m 3. Remove the rear wheel bearing and inner wheel
(28-38 Ib-ft) as shown. Tighten the cover bolts in bearing oil seal (1177) as a unit, using the slide
a cross-wise pattern to make sure cover is drawn hammer.
down uniformly. lighten the ratio tag hold-down
bolt to 24-38 N·m (18-28Ib-ft).
TIGHTEN BOLTS
TO 38-52 N·m
(28-38 FT-LB)
Installation
1. CAUTION: Installation of the rear wheel
E5865·C bearing or seal assembly without the proper
tool may result in an early bearing or seal
7. For in-vehicle repairs, add lubricant through the failure. If seal becomes cocked in the bore
filler hole until the lubricant level reaches the during installation, remove it and install a
bottom of the filler hole with the axle in the running new one.
position (approximately 6.5 U.S. pints). For
out-of-vehicle repairs, add 7.5 U.S. pints of Lubricate the new rear wheel bearing with rear
lubricant. Use Rear Axle Lubricant axle lubricant and install the rear wheel bearing
XV-80W90-QL or equivalent meeting Ford into the housing bore using Driver Handle
specification WSP-M2C 197-A for conventional T80T-4000-W and Rear Axle Seal Replacer
axles, plus 8 ounces of Additive Friction Modifier T80T-4000-V.
F3TZ-19B546-MA or equivalent meeting Ford 2. Coat the lips of the inner wheel bearing oil seal
specification WSP-M2C 196-A for complete refill with Premium Long-Life Grease XG-1-C or -K or
of Limited Slip applications. equivalent meeting Ford specification
8. Road test the vehicle. ESA-M 1C75-B and using the Driver Handle and
Rear Axle Seal Replacer used to install the rear
wheel bearing, install the inner wheel bearing oil
seal.
Oil Seal and Wheel Bearing, Semi-Floating
REAR AXLE
Axle SEAL REPLACER
NOTE: For full-floating axle service procedures, refer TaOT-4000-Y
to Section 05-02B.

Impact Slide Hammer T50T-100-A
Axle Bearing Remover T85T-1225-AH
Driver Handle T80T-4000-W
Rear Axle Seal Replacer T80T-4000-Y
Removal
1. Remove axle. Refer to Axle Shaft, Semi-Floating
Axle, Removal and Installation in this section.
2. Using Impact Slide Hammer T50T-100-A and Axle
Bearing Remover T85T-1225-AH, insert into the
bore as shown and position behind the rear wheel
bearing (1225) so the tangs on the tool engage -"
I
the outer race of rear wheel bearing.

E5868-C

ALL RIGHTS RESERVED
Differential Case and Drive Pinion 3. Loosen the differential bearing cap bolts and
bearing caps.
Companion Flange Holding Tool T57T-4851-B
Pinion Shaft Thread Protector T85T-4209-AH
Pinion Bearing Core Remover T71 P-4621-B
Removal
1. NOTE: Before removing the differential case
(4204), check the ring gear runout as described
in the Cleaning and Inspection portion of this
section. If ring gear runout exceeds O. 101 mm
(0.004 inch), the differential case and ring gear
must be removed to perform the Differential
Runout Check. The Differential Runout Check will
isolate the cause of excessive ring gear runout.
Remove the axle shafts (4234) as described in
E4763-D
this section (semi-floating axles) or in Section
05-02B (full-floating axles). 4. CAUTION: When using the pry bar, place a
2. CAUTION: Right and left bearing retaining wood block between the pry bar and the axle
caps must not be interchanged. housing to protect the machined surface
NOTE: The direction of triangles on bearing from damage.
retaining caps must be noted. When Pry the differential case, rear pinion bearing cups
reassembled, the triangles must be pointing in the and differential bearing shims (4067) out until
same direction (outboard) as before removal. they are loose in the bearing caps. Remove the
Mark one bearing retaining cap to make sure the bearing caps and remove the differential
caps are installed in their original positions during assembly from the carrier.
assembly.
WOOD BLOCK'
E5870-1A
E4707·1C

ALL RIGHTS RESERVED
5. CAUTION: Do not damage anti-lock speed 7. Mark the driveshaft (4602) in relation to the rear
sensor ring when removing ring gear. If axle companion flange. Remove the drive
anti-lock speed sensor ring is removed from shaft-to-axle-companion flange U-bolts and nuts.
case, it must be replaced with a new one. Wrap universal joint with tape and position
If required, remove the bolts that attach the ring driveshaft out of the way.
gear to the differential case. Remove the ring
gear from the case by striking at alternate holes REAR AXLE
around the gear. COMPANION
FLANGE-4851
E5871-B
8. Install an inch-pound torque wrench on the pinion

nut. Record the torque required to maintain
E7210-C rotation of the pinion through several revolutions.
6. If required, remove the anti-lock speed sensor
ring with a soft-faced hammer. Discard the
anti-lock speed sensor ring.
"E8738-A
E7206-C
ALL RIGHTS RESERVED
9. ~ NOTE: Scribe a mark on the rear axle companion

flange and pinion stem for alignment during
assembly.
Install Companion Flange Holding Tool
T57T-4851-B on the rear axle companion flange
and remove the pinion nut.
COMPANION FLANGE
HOLDING TOOL
T57T-4851-B
PINION SHAFT
THREAD
PROTECTOR
T85T-4209-AH
E5874-1A
13. CAUTION: Use care not to damage seal bore

in housing when prying, gripping or striking.
Pry up on metal flange of pinion seal. Install
gripping pliers and strike with hammer until pinion
seal is removed.
E5872-e
10. Remove the rear axle companion flange using

Puller D80L-1002-L or equivalent.
PULLER
D80L-1002-L
OR EQUIVALENT
E5873-C
11. With a soft-faced hammer, drive the pinion out of

the front bearing cone and remove it through the
rear of the housing.
12. If available, install Pinion Shaft Thread Protector
T85T-4209-AH on the pinion threads and drive
the pinion from the housing. Care should be taken
not to allow the drive pinion to fall from the
housing.
ALL RIGHTS RESERVED
OS-02A-13 Axle, 10.2S-lnch Ring Gear 05-02A·13
14. Remove oil slinger and drive pinion bearing cone

and roller from axle housing.
FRONT BEARING
CONE AND
ROLLER-4621
E.732-C
17. NOTE: Measure the pinion shim, which is found

E6612·D under the bearing cone, with a micrometer and
record the thickness (as a reference to be
15. NOTE: Do not remove the pinion bearing cups compared to the shim gauge reading prior to
from the carrier casting unless the cups are installing the bearing).
damaged.
Remove the pinion shim from the drive pinion.
If the pinion bearing cups are to be replaced, tap
alternately (with a brass drift of suitable length)
on opposite sides of the cup during removal to
prevent cup from cocking in the casting. REAR CONE
DRIVE PINION AND ROLLER
4209 BEARING-4630
DRIVE PINION
BEARING ADJUSTMENT
SHIM
4663 E587~B
Differential Runout Check

If the ring gear runout check (before disassembly)
E5877-B exceeds specification, the condition may be caused
by a warped ring gear, a damaged case, excessively
16. To remove the rear cone and roller bearing, use worn differential bearings or foreign material between
Pinion Bearing Cone Remover T71 P-4621-B as mating surfaces (burrs, shavings, etc.). To determine
shown. the cause of excessive runout, proceed as follows:
1. Remove the differential case from the axle
housing (refer to Differential Case and Drive
Pinion Removal in this section) and remove the
bolts that attach the ring gear to the differential
case (4204). Remove the ring gear from the case
with a hammer and a drift.
ALL RIGHTS RESERVED
2. Install the differential assembly including the

bearing cups and shims in the axle housing.
lighten the differential bearing cap bolts to
109-129 N·m (80-95Ib-ft).
DIFFERENTIAL
ASSEMBLY
ES88O-1C
5. NOTE: When installing new bearings, press
against the bearing cone only.
Install new differential bearings on the case hubs
using Differential Bearing Cone Replacer
081 T-4221-A or equivalent and install the
DIFFERE NTIAL differential assembly in the carrier without the
BEARING ring gear.
4221 E5879-D
6. Check the case runout again with the new
3. Rotate assembly to make sure differential bearings. If the runout is now within limits, use the
bearings (4221) seat properly. new bearings for assembly. If the runout is still
excessive, the case is damaged and should be
replaced.
Pinion Bearing Cups, Front and Rear

Pinion Bearing Cup Replacer (Front) T85T-4616-AH
Pinion Bearing Cone Replacer T85T-4621-AH
Axle Bearing / Seal Plate T75L-1165-B
Pinion Seal Replaqer T83T-4676-A
Companion Flange Replacer T85T-4851-AH
Shim Driver T85T-4067-AH
ROTATE
4. Check the runout of the differential case flange

with Dial Indicator TOOL-4201-C.lf the runout is
within specification (0.076mm [0.003 inch]
maximum), install a new ring and pinion gear. If
the runout exceeds specification, the ring gear is
true and the trouble is due to either a damaged
case or bearings. Visually inspect the bearings. If
bearings are not damaged, replace both the case
and bearings. Recheck the runout with new parts
(case and bearings).

ALL RIGHTS RESERVED
OS-02A-1S Axle, 10.2S-lnch Ring Gear OS-02A-15
Installation
1. Drive the front pinion bearing cup into the axle
housing using Pinion Bearing Cup Replacer
(Front) T85T-4616-AH and Driver Handle
T80T-4000-W.
Drive Pinion Shim Selection

1. Individual differences in machining the rear axle
2. Drive the rear pinion bearing cup into the axle differential carrier casting and the ring gear and
housing using Pinion Bearing Cup Replacer (Rear) pinion and variation in bearing widths require a
081 T-4616-A and Driver Handle 081 L-4000-A or pinion shim between the pinion rear.b~aring and
equivalents. pinion head, in order to locate the pinion for
correct tooth contact with the ring gear.
REAR PINION
BEARING CUP PINION BEARING When replacing a ring and pinion gear, the correct
4628 CUP REPLACER shim thickness for the new gear set to be
(REAR)
D81T-4616-A installed is determined by the following procedure
OR EQUIVALENT using the tools listed below.
Rear Axle Pinion Depth Gauge To~ls
E6&53-C
E5883-e
3. Make sure the cups are properly seated in their Part

bores. If a 0.038mm (0.0015 inch) feeler gauge Item Number Description
can be inserted between a cup and the bottom of
1 T80T-4020-F42 Gauge Block
its bore at any point around the cup, the cup is not
properly seated. Whenever the cups are 2 T78P-4020-A 15 Gauge Disc
replaced, the differential pinion bearing (4621) 3 4621 Differential Pinion Bearing
should also be replaced. (Outer)
4 T76P-4020-A 11 Handle
(Inner)
6 T80T-4020-F43 Screw
(Continued)

ALL RIGHTS RESERVED
05-02A-16 Axle, 10.2S-lnch Ring Gear OS-02A-16
7. NOTE: Pinion shims must be flat. Do not use dirty,

Part bent, nicked or mutilated pinion shims as a gauge.
Utilize pinion shims as the gauge for shim
7 T76P-4020-A3 Aligning Adapter selection. This will minimize errors in attempting
8 D80T-4020-F48 Gauge Tube to stack feeler gauge stock together or simple
addition errors in calculating correct shim
REAR AXLE PINION DEPTH GAUGE TOOLS thickness. A slight drag should be felt on the
pinion shim for correct selection. Do not force the
Tool Number Description
pinion shim between the gauge block and the
T85T-4020-AH 1 Aligning Adapter gauge tube. This will minimize selection of a pinion
T80T-4020-F43 Screw shim thicker than required which results in a deep
tooth contact in final assembly of integral axles.
T80T-4020-F42 Gauge Block
T76P-4020-A 11 Handle
T85T-4020-AH2 Gauge Disc
D81T-4020-F51or Gauge Tube
Equivalent
2. Assemble the aligning adapter, gauge disc and

gauge block to the screw.
3. Place the front cone and roller bearing (new, or
used if in good condition) over the aligning tool
and insert it into the rear axle pinion bearing cup
(4628) of the carrier.
4. Place the front bearing into the pinion bearing cup
and assemble the tool handle into the screw.
5. Roll the assembly back and forth a few times to
seat the bearings while tightening the tool handle
by hand. Tighten the tool handle to 27 N·m (20
Ib-ft). The gauge block must be offset as shown
(45 degrees) to obtain an accurate reading.
PINION DEPTH
~. GAUGE BLOCK
T80T-4020-F42
Part
1 4621 Front Bearing Cone and
Roller
2 T80T-4020-F43 Screw
3 4630 Drive Pinion Bearing Cone
and Roller
4 T85T-4020-AH2 Gauge Disc
6 D81T-4020-F51 Gauge Tube
7 T85T-4020-AH 1 Aligning Adapter
8 4010 Axle Housing
e--1A 9 T76P-4020-A 11 Handle
6. Center the gauge tube into the differential bearing

bore. Install the bearing retaining caps and tighten
the bolts to 95-115 N·m (70-85 Ib-ft). Bearing
retaining caps are to be installed with the
triangles pointing outboard.

ALL RIGHTS RESERVED
8. NOTE: The same cone and roller bearing used in

the following procedure must be used in final
assembly of the axle.
NOTE: Be sure that press load is not applied to
the bearing cage.
Place the selected shim(s) on the pinion and
press the bearing cone and roller until it is firmly
seated on the shaft using Inner Pinion Bearing
Cone Replacer T85T-4621-AH and Axle
Bearing/Seal Plate T75L-1165-B.
PINION
STEM
SHOULDER
PINION DRIVE
GEAR PINION
BEARING
CONE-4630
E5889-D
11. CAUTION: Installation without the proper tool

INNER~- __~ ~.. may result in early seal failure. If pinion seal
PINION BEARING ~~==~'T}JI becomes cocked during installation, remove
CONE REPLACER
T85T-4621-AH it and install new one.
Install the drive pinion bearing cone and roller and
oil slinger in the housing bore and install the pinion
---- seal on the Pinion Seal Replacer T83T-4676-A.
BEARING CONE AND ROLLER

4621
9. Check splines on the pinion stem to be sure they

are free of burrs. If burrs are evident, remove
them by using a fine crocus cloth, working in a
rotational motion. Wipe the pinion clean.
10. Place the collapsible spacer on the pinion stem
against the pinion stem shoulder.
PINION SEAL
~------------REPLACER
T83T-4676-A E5876-D
12. Clean the seat surface of the pinion seal.

13. Install the pinion seal in the housing bore using
Pinion Seal Replacer T83T-4676-A.
1995 F-150, F-~50, F-350, Bronco, F-Super Duty Powertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
14. Coat the lips of the pinion seal with Premium

PINION SEAL
REPLACER
T83T-4676-A
16. Apply a small amount of lubricant to the rear·axle

companion flange shaft splines. Align the mark on
the rear axle companion flange with the mark on
the pinion stem.
17. NOTE: If a new rear axle companion flange is
E5891-D being installed, disregard the scribe mark on the
pinion stem.
15. From the rear of the axle housing, install the drive
pinion, shim(s), rear bearing cone and roller, and NOTE: The rear axle companion flange must
collapsible spacer into the housing pinion shaft never be hammered on or installed with power
bore. tools.
With the drive pinion in place in the axle housing,
install rear axle companion flange using
Companion Flange Replacer T85T-4851-AH.
Rear Axle Companion Flange Installation
COMPANION FLANGE
REPLACER
T85T-4851-AH
VIEW A
E5893·2A
1995 F-150, F-250, F-350, Bronco, F-Supet puty Powertrain, Drivetrain'july 1994
ALL RIGHTS RESERVED
18. Hold the rear axle companion flange with 20. CAUTION: Tab on anti-lock speed sensor ring
Companion Flange Holding Tool T57T-4851-B must be aligned with slot in differential case
while tightening the nut. (4204).
Start two ring gear bolts through the case into the
ring gear to make sure ring gear bolt holes align
with case bolt holes properly.
COMPANION FLANGE
HOLDING TOOL
T57T-4851 -B
AND BREAKER BAR
E5894-B
19. Tighten the pinion nut, rotating the pinion

occasionally to make sure cone and roller
bearings are seating properly. Take frequent
cone and roller bearing torque preload readings
until the original recorded preload reading is
obtained by rotating the pinion with a N·m
(inch-pound) torque wrench.
If the original recorded preload is lower than
specification (original bearings .9-1.5 N·m [8-14
Ib-in]; new bearings 1.8-3.3 N·m [ 16-29 Ib-in]),
tighten to specification. If the preload is higher
than specification, tighten to original reading as
recorded.
Under no circumstances should the pinion nut be
backed off to reduce preload. If reduced preload
is required, a new collapsible spacer and pinion
nut must be installed.
VIEW A
PINION BEARING TORQUE
PRELOAD CHECK E7207-D
Part
TORQUE WRENCH Item Number Description
(INCH POUND)
1 3L222 Ring Gear Bolts
2 4B409 Anti-Lock Speed Sensor
Ring
3 4209 Ring Gear
4 - Anti-Lock Speed Sensor
Ring Tab (Part of 4B409)
5 - Differential Case Slot
(Part of 4204)
ES895-1A
ALL RIGHTS RESERVED
21. Press the anti-lock speed sensor ring and ring

gear.on the differential case. The ring gear acts
as a pilot for the anti-lock speed sensor ring.
Apply Threadlock and Sealer EOAZ-19554-AA
(WSK-M2G315-A5) or equivalent to ring gear
bolts and tighten to 136-163 N·m (100-120 Ib-ft).
1~4-------5.4 I N C H E S - - - - - - -... I
E5896-1 A
25. Install a 6.73mm (0.265 inch) shim on left side.
6.73MM
(0.265 INCH)
SHIM-4067
22. With pinion depth set and pinion installed, place

differential case (with ring gear, anti-lock speed
sensor ring, thrust washers, differential side
gears (4236), bearings and cups) in carrier.
DIFFERENTIAL 26. Install left bearing cap and tighten bolts

finger-tight.
23. To simplify installation, fabricate two differential

case retaining straps from metal stock as shown.
These retaining straps will prevent the differential
from falling out of the axle housing.
24. Attach the straps at the 11 o'clock and 1 o'clock
positions in the cover bolt holes. Install bolts and
rotate straps to contact the bearing cups. Make
sure access is available for shim installation.

ALL RIGHTS RESERVED
05-02A-21 Axle, 10.25-lnch Ring Gear 05-02A·21
27. NOTE: Apply pressure toward left side to make

sure that the left bearing cup is seated.
ROTATE
Install progressively larger shims on the right side
until the largest shim selected can be installed by
hand.
E9081·A
30. Check ring gear and pinion backlash with a Dial

28. NOTE: Triangles on bearing cap must point Indicator TOOL-420 1-C or equivalent.
outboard. If the backlash is 0.20-0.38mm (0.008-0.015
Install right side bearing retaining cap and tighten inch) (0.30-Q.38mm [0.012-0.0 15 inch]
bearing cap bolts to 95-115 N·m (70-85Ib-ft). preferred), proceed to Step 36.
If the backlash is zero, proceed to Step 31.
If the backlash is 0.025-0. 177mm (0.001-0.007
inch) or greater than 0.38mm (0.015 inch),
proceed to Step 32.
DIAL INDICATOR
TOOL-4201-C
E9079-B
29. Rotate assembly to make sure it rotates freely.
E5897-B

ALL RIGHTS RESERVED
31. If a zero backlash condition occurs, add 0.50mm

(0.020 inch) to the right side and subtract DIAL INDICATOR
0.50mm (0.020 inch) from the left side. TOOL-4201-C
SUBTRACT
0.5 MM (0.020 IN.)
E4756-B
E5897-B
32. Recheck backlash. If backlash is within
specification, go to Step 37. If backlash is not 33. If backlash is 0.025-0. 177mm (0.001-0.007
within specification, proceed to Step 33. inch), or greater than 0.38mm (0.015 inch),
correct backlash by increasing thickness of one
shim and decreasing thickness of the other shim
by the same amount. Refer to Backlash and Shim
Change Chart.
BACKLASH AND SHIM CHANGE CHART
Backlash Change Required Thickness Change Required Backlash Change Required Thickness Change Required
mm Inches mm Inches mm Inches mm Inches
.025 .001 .050 .002 .228 .009 .304 .012
.050 .002 .050 .002 .254 .010 .355 .014
.076 .003 .101 .004 .279 .011 .355 .014
.101 .004 .152 .006 .304 .012 .406 .016
.127 .005 .152 .006 .330 .013 .457 .018
.152 .006 .203 .008 .355 .014 .457 .018
.178 .007 .254 .010 .381 .015 .508 .020
.203 .008 .254 .010 - - - -
ALL RIGHTS RESERVED
1
1
r
MORE BACKLASH
LESS BACKLASH + ROTATE
DECREASE (- )INCREASE (+) DECREASE (-) INCREASE (+ J
FOR MORE FOR LESS FOR LESS FOR MORE
BACKLASH BACKLASH BACKLASH BACKLASH
LEFT SIDE RIGHT SIDE
34. NOTE: Triangles on bearing caps must point

outboard.
Install shim and bearing retaining caps. Tighten E9081-A
cap bolts to 109-128 N·m (80-95 Ib-ft). 36. Recheck backlash. If backlash is within
specification, go to Step 37. If backlash is not
within specification, repeat Step 33.
Backlash specification: 0.20-0.38mm
(0.008-0.015 inch). Preferred range:
0.30-0.38mm (0.012-0.015 inch).
DIAL INDICATOR
TOOL-420'-C
35. Rotate assembly several times to make sure

differential bearings seat properly.
E5897·B
ALL RIGHTS RESERVED
05-02A-24 Axle, 10.2S-lnch Ring Gear OS-02A-24
37. Remove bearing caps and bolts. To establish

differential bearing preload, increase both left and
right shim sizes by O. 152mm (0.006 inch). Make
sure shims are fully seated and assembly turns
freely.
INCREASE INCREASE
SHIM BY SHIM BY
0.152 MM (0.006 INCH) 0.152 MM (0.006 INCH)
40. Install the driveshaft (4602). Align the scribe

marks on the rear axle companion flange and axle
shaft (4234) and connect the driveshaft.
4 1. Tighten attaching bolts and nuts to 11-20 N·m
(8-15 Ib-ft).
42. Install the axle shafts and carrier cover. Refer to
E4758·E
Axle Shaft, Semi-Floating Axle, Removal and
38. Install the shims by driving into position with Shim
Driver T85T-4067-AH.
Axle Housing
Removal
Remove the rear wheels and tires and the brake
drums.
2. Remove rear anti-lock sensor hold-down bolt, and
carefully remove rear brake anti-lock sensor
(2C 190). Refer to Sensor Indicator, Anti-Lock
Brake, Removal and Installation in this section.
.3. Mark the driveshaft axle end flange and the rear
axle companion flange to make sure driveshaft
(4602) is positioned properly during assembly.
Disconnect the driveshaft from the rear axle
companion flange. Remove the driveshaft..
4. Remove axle shafts (4234) (semi-floating axle) or
rear hub (1109) (full-floating axle).
5. Disconnect brake lines at wheel cylinders.
SHIM DRIVER
T85T-4067-AH 6. Remove the four retaining nuts from each backing
plate.
E9238-A
39. NOTE: Triangles on bearing caps must point

outboard.
Install bearing caps and tighten cap bolts to
109-128 N·m (80-95Ib-ft). Recheck backlash. If
not to specification, repeat Step 29.
ALL RIGHTS RESERVED
7. The axle vent is secured to the housing assembly

through the brake junction block. Disconnect the
vent hose from the vent and the vent from the rear
axle housing.
BRAKE AND
FUEL LINE
TUBING
2269
U-BOLTS
E473O-C
E4726-C
8. Disengage the brake line from the clips that retain

the line to the' axle housing and carrier.
SHOCK ABSORBER
LOWER BOLT
AND NUT
E4729·1A
Installation
1. Raise the axle housing into position so that the
rear spring caps and plates (5796) can be
installed. Tighten the U-bolt nuts to the
specification listed in Section 04-02 of the Body,
Chassis Manual.
E4728-B
9. Remove the hydraulic brake junction block and

brake lines from the axle housing.
U-BOLTS
E473O-C
2. Connect the shock absorber lower bolts to the
mounting bracket on the axle housing. Install the
attaching nuts and tighten to the specification
listed in Section 04-02 of the Body, Chassis
Manual.
10. Support axle housing on a jack, and then remove 3. Insert the vent fitting into the hydraulic junction
the U-bolt nuts. Remove the U-bolts and plates. block and position the assembly over the housing
11. Disconnect the shock absorber lower bolts from vent hole. Hand start the vent fitting and tighten to
the mounting brackets on the axle housing. 20 N·m (15Ib-ft).
12. Remove the axle housing from the vehicle.
ALL RIGHTS RESERVED
05-02A-26 Axle, 10.2S-lnch Ring Gear 05-02A-26
4. Position the brake lines to the axle housing and b. Install hold-down bolt and tighten to 34-40
secure with the retaining clips at the right axle N·m (25-30 Ib-ft).
tube and vent fitting through the junction block. 2. If old rear brake anti-lock sensor is to be
Attach brake lines to wheel cylinders and bleed reinstalled, clean and blow off metal particles
brake system. Refer to Section 06-00 of the using compressed air.
Body, Chassis Manual.
a. Remove and replace O-ring with a new
5. Install the brake backing plates on the rear axle O-ring.
housing flanges (no gaskets required). lighten
the attaching bolts to 68-115 N·m (50-85Ib-ft). b. Apply a light film of motor oil to O-ring.
6. Align the scribe marks on the rear axle c. Firmly grasp rear brake anti-lock sensor at
companion flange and driveshaft and connect the sides (do not install by applying force on
driveshaft. lighten attaching bolts and nuts to connector) and push into axle housing,
11-20 N·m (8-15Ib-ft). aligning mounting flange hole with threaded
hole in axle housing.
7. Install rear brake anti-lock sensor. Refer to
Sensor Indicator, Anti-Lock Brake, Removal and d. Install hold-down bolt and tighten to 34-40
Installation in this section. N·m (25-30 Ib-ft).
8. Install the brake drums.
HOLD DOWN
9. Install the wheel and tire assembly. lighten the BOLT-390356
wheellugnuts to 190 N·m (140 Ib-ft). Install the - - - - TIGHTEN TO
wheelcovers. 34-41 N·m
(25-30 FT-LB) REAR
, .... ANTI-LOCK
SENSOR
2L373
~~----- O-RING
AXLE
;..e-_-- HOUSING
4010
E7209·D
E4728-B
Sensor Indicator, Anti-Lock Brake Differential Case

Removal Disassembly
1. Remove rear anti-lock sensor hold-down bolt. 1. Refer to Inspection Before Disassembly in the
Remove rear brake anti-lock sensor (2C190). Cleaning and Inspection portion of this section.
2. Clean axle mounting surface, using caution to 2. If required, remove the ring gear, anti-lock speed
prevent dirt from entering axle housing. sensor ring, differential side gears (4236), pinion
Installation gears and thrust washers.
1. If new rear brake anti-lock sensor is to be
installed, lightly lubricate O-ring with motor oil.
a. Firmly grasp rear brake anti-lock sensor at
sides (do not install by applying force on
connector) and push into axle housing,
aligning mounting flange hole with threaded
hole in axle housing.

ALL RIGHTS RESERVED
05·02A·27 Axle, 10.25-lnch Ring Gear 05-02A-27
3. Remove the differential case (4204) from the axle 2. CAUTION: Before performing the following
housing and remove the differential bearings from step, refer to installation procedures in this
the case using Puller D80L-1002-L and Step section for installation of ring gear and
Plate D80L-630-7 or equivalents. anti-lock speed sensor ring.
CAUTION: Extreme care should be taken not
to scratch, dent, chip or otherwise cause
damage to speed sensor ring or teeth while
handling or during assembly.
Press the ring gear and anti-lock speed sensor
ring onto the differential case, and install the
attaching bolts. lighten the bolts to 135-162 N·m
( 100-120 Ib-ft).

DIFFERENTIAL
BEARING Inspection Before Disassembly
4221
Rear Axle Pinion Depth Gauge Tool Set T79P-4020-A
The differential case and drive pinion should be

inspected before they are removed from the carrier
E5925-B casting. These inspections can determine the cause of
the concern and the resolution.
4. Refer to Inspection After Disassembly in the 1. Wipe the lubricant from the internal working parts
Cleaning and Inspection portion of this section. and visually inspect the parts for wear and / or
Assembly damage.
1. Install differential bearings on the rear hubs 2. Rotate the gears to see if there is any roughness
(1109) using Differential Bearing Cone Replacer which would indicate damaged bearings or gears.
081 T-4221-A or equivalent. Press against the 3. Check the ring gear teeth for signs of scoring,
bearing cone only. abnormal wear nicks of chips.
DIAL INDICATOR
WITH BRACKETRY
~-- PRESS RAM TOOL-4201-C
DIFFERENTIAL
BEARING CONE
REPLACER - -........
D81T-4221-A
OR EQUIVALENT
DIFFERENTIAL
l'lfi~~~~~- BEARING-4221
E8001-D
SPEED
SENSOR
RING
48409
RING GEAR BACKFACE RUNOUT
REAR ANTI-LOCK BRAKE VEHICLES E7162.E

ALL RIGHTS RESERVED
OS-02A-28 Axle, 10.2S-lnch Ring Gear 05-02A-28
4. NOTE: There is a space provided between the

anti-lock speed sensor ring and the ring ,gear for
measuring ring gear backface runout.
Set uP. a diai indicator and check ring gear
backlash. Backlash should be 0.20-0.38mm
(0.008-0.015 inch), with 0.30-0.38mm
(0.012-0.015 inch) preferred.
5. To check ring gear backface runout, mount Dial
Indicator with Bracketry TOOL-4201-c on the
carrier so the tip of the dial indicator contacts the
backface of the ring gear. Backface runout
should be no more than 0.101mm (0.004 inch).
, DIAL
INDICATOR
TOOL-4201-C
Bearing Cups
Check bearing cups for deep score$, galling, or
spalling.lf a 0.0381mm (0.0015 inch) feeler gauge
can be inserted between a cup and the bottom of its
bore at any point around the cup, the cup must be
re-seated.
RING GEAR BACKLASH
E9082-A
6. A contact pattern is not an acceptable guide to

check for noise.· Ring gear and pinion must be
checked using tt;le Rear Axle Pinion Depth Gauge
Tool set T79P-4020-A which shows the correct
pinion shim required to assure acceptable running
condition.
Inspection After Disassembly Cone and Roller Assemblies

1. Thoroughly clean all parts. Always use new When operated in the cups, bearing rollers must turn
solvent when cleaning bearings. Do not spin dry without roughness. Examine the roller ends for step
bearings with compressed air. wear. If inspection reveals either a damaged cup or a
2. Oil the bearings immediately to prevent rusting. damaged cone and roller assembly, both parts should
be replaced.
3. Inspect the parts for any major damage.
4. Clean the inside of the axle housing before
Companion Flange
rebuilding. When a scored or chipped gear set is Be sure that the flange half-rounds and lugs have not
replaced, the axle housing must be washed been damaged in removing the driveshaft (4602) or in
thoroughly. Inspection procedures for individual removing the rear axle companion flange from the
parts follow. pinion. The end of the flange that contacts the bearing
cone as well as the nut counterbore and seal surface
must be smooth and free of nicks.
1995 F-150. F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
Gears Differential Case

Examine the pinion and ring gear teeth for scoring, Make sure that the rear hubs (1109) where the
excessive wear, nicks and excessive chipping. Worn, bearings mount are smooth. Carefully examine the
scored and damaged gears cannot be rebuilt to differential case bearing shoulders, which may have
correct a noisy condition. been damaged when the bearings were removed. The
bearings will fail if they do not seat firmly against the
Carrier Housing shoulders. Check the fit (free rotation) of the
Make sure that the differential and pinion bearing differential side gears (4236) in their counterbores.
bores are smooth. Remove any nicks or burrs from the Check for cracks in thrust washers.
mounting surfaces of the carrier housing.
SPECIFICATIONS
LUBRICANT CAPACITIES AND CHECKING PROCEDURES (INTEGRAL CARRIER)

Approximate Lubricant Capacity (In-Vehicle Repair) eb
Vehicle Axle U.S. Pints Imperial Pints Liters
F-250, F-350 Regular & Chassis ed
10.25-lnch Ring Gear 6.5 5.4 3.0
CAB, F-250, F-350 H.D.
a Ford design conventional Axles use Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.
b Service refill capacities are determined by filling the axle with the specified lubricant to the bottom of the filler hole with the vehicle in
running position.
c Plus 8 oz. (U.S. measure) additive friction modifier, F3TZ-19B546-MA or equivalent meeting Ford specification WSP-M2C 196-A for
Limited Slip applications.
d Rear axle lube quantities must be replaced every 100,000 miles (160000 km) or if the axle has been submerged in water. Otherwise, the
lube should not be checked or changed unless a leak is suspected or repair required.
NOTE: 6.5 pints of lubricant is the fill specification when the axle is installed in the vehicle. If the axle is out of the
vehicle, fill with 7.5 pints of specified lubricant.
CLEARANCE, TOLERANCE AND ADJUSTMENTS TORQUE SPECIFICATIONS (INTEGRAL CARRIER)

(INTEGRAL CARRIER)
Description mm Inches
Differential Bearing Cap Bolt 109-129 80-95
Maximum Runout of Backface 0.101 0.004
Lock Pin Using Loctite@ 20-40 15-30
of Ring Gear
EOAZ-19554-B or Equivalent
Maximum Runout of Backface 0.076 0.003
Ring Gear Attaching Bolts Using 136-163 100-120
of Differential Case Flange
Loctite@ EOAZ-19554-B
Differential Side Gear Thrust 0.76-0.81 0.030-0.032 or Equivalent
Washer Thickness
Rear Cover Screw 38-52 28-38
Differential Pinion Gear Thrust 0.76-0.81 0.030-0.032
Ratio Tag Hold-Down Bolt 24-38 18-28
Washer Thickness
Oil Filler Plug 20-40 15-30
Nominal Pinion Locating Shim 0.76 0.030
Brake Backing Plate Nuts - F-250 68-95 50-70
Available Pinion Gear Shims in 0.53-0.94 0.021-0.037
Steps of 0.00 1 Inch Driveshaft to Rear Axle Companion 11-20 8-15
Flange
Backlash Between Ring Gear 0.20-0.38 0.008-0.015
& Pinion Teeth (0.30-0.38 (0.012-0.015 Axle Vent 20 15
Preferred) Preferred) Wheel Lugnut (Both Single and 190 140
Maximum Backlash Variation 0.101 0.004 Dual Rear Wheel)
Between Teeth Rear Anti-Lock Sensor Bolt 34-40 25-30
Maximum Radial Runout of 0.304 0.012 T.I.R.
Rear Axle Companion Flange
in Assembly
Sensor Pole to Top of Sensor 0.127-1.143 0.005-0.045
Ring Gap
Maximum Axle Shaft End Play 0.762 0.030
(Semi-Float Axles Only)

ALL RIGHTS RESERVED
ADJUSTMENT TORQUE SPECIFICATIONS SPECIAL SERVICE TOOLS REQUIRED (Cont'd)

(INTEGRAL CARRIER)
Tool Number /
Rotational Torque- Description illustration
Description N·m Lb-In T85T-4067-AH
Shim Driver
~
Pinion Bearing Preload -
Collapsible Spacer
- Used Bearings .9-1.5 8-14
- New Bearings 1.8-3.3 16-29 TUT-4087-AH
a Rotational torque taken on pinion nut with inch-pound torque
wrench with pinion seal installed. T85T-4209-AH
Pinion Shaft Thread Protector

~
TUT-42C»-AH
SPECIAL SERVICE TOOLS REQUIRED T85T-4616-AH

Pinion Bearing Cup Replacer
Tool Number/
Description Illustration @
T50T-100-A TasT-411I-AH
~
Impact Slide Hammer
n
T71P-4621-B
T50T·1OG-A Pinion Bearing Cone Remover
T75L-1165-B ~ ~
~17!IL-11""
T71P-4621-B
T85T-1225-AH T85T-4621-AH
Inner Pinion Bearing Cone
~ ~
Axle Bearing Remover
Replacer
TIST·1225-AH TI5T-4121-AH
T80T-4000-W T83T-4676-A
~
Driver Handle Pinion Seal Replacer
TIOT-40CJ0.W
Q@
T80T-4000-Y TI3T-4871·A
Rear Axle Seal Replacer
®
T57T-4851-B
T80T-4OOG-Y
.~
T57T-4151-8
T79P-4020-A
Pinion Depth Gauge Kit T85T-4851-AH
~
"" n
V Companion Flange Replacer
~ TUT-4151-AH
~~~
lit
.=~
~ . , ~"'
j
[J
~
~ €I TOOL-420 1-C Dial Indicator with Bracketry
T79P-402Q..A
(Continued)
ALL RIGHTS RESERVED
05-02B-1 Wheel Hubs and Bearings, Ford Full-Floating Axle 05-02B-1
SECTION 05-02B Wheel Hubs and Bearings, Ford

Full-Floating Axle
VEHICLE APPLICATION .••••.•••••.••.•..•••••.•••.•.•.•••.•••••••05-02B-1 DISASSEMBLY AND ASSEMBLY
DESCRIPTION AND OPERATION Rear Hub, Full-Floating Axle •.•..•...•••.•....••••.••••.••.••05-02B-9
Hub Assembly, Full-Floating .•••.•.•••.•.•••.••.•••••..•••••05-02B-1 SPECIFICATIONS ••.•••••••••••••••.••.••..•••..•••.•••.••••..••.••05-02B-14
DIAGNOSIS AND TESTING •••••••.•.••....•••••..•..•••••.•...••.05-02B-3 SPECIAL SERVICE TOOLS/EQUIPMENT ..••••••..••.•••05-02B-14
Axle Shaft, Rear Hub, 011 Seal and Outer Wheel
Bearing ••••••••••••••••••••••••••••..•.••.•..••.••.••.•.•••..••••••05-02B-3
VEHICLE APPLICATION
F-250 HD and F-350 Vehicles
Hub Assembly, Full-Floating

The full-floating rear axle features brake drums that
are mounted outboard of the rear hub (1109).
Therefore, when brake inspection or replacement is
required the rear hub need not be removed.
The rear hub is supported or floats on the axle spindle
on two opposed tapered roller bearings. It is retained
on the spindle by a ratcheting nut that is tabbed to a
slot on the spindle. If, for any reason, the rear hub is
removed from the spindle, the old hub seal must
be removed and a new hub seal installed.
ALL RIGHTS RESERVED
~ Wheel Hub and Bearing Assembly, Ford Full-Floating Axle
27
DUAL REAR WHEEL VEHICLES
SAME AS MAIN VIEW EXCEPT AS SHOWN
E8736-D
Part Part
1 46053-S100 Bolt 16 1240 Rear Wheel Bearing Outer
2 4238 Axle Shaft (LH) Cone and Roller
2 4235 Axle Shaft (RH) 17 4A331 O-Ring
3 1126 Brake Drum 18 1012 Lugnut, Dual Rear Wheel
Integral Two-Piece
4 1A124 Hub Nut (Right-Hand Thread
for Right Axle Tube, 19 - Outside Wheel
Left-Hand Thread for Left (Part of 1001)
Axle Tube) 20 - Wheel Pin Is Inserted
5 1239 Rear Wheel Bearing Outer Through Drum and Hub
Cup 21 - Locating Pin in Wheel
6 1244 Rear Wheel Bearing Inner 22 - 4 Clearance Holes in Drum
Cone and Roller for Wheel Pin and Hub
7 1250 Rear Wheel Bearing Oil 23 - 2 Wheel Pin Locating Holes
Slinger 24 - Hub Locating Pin Is Inserted
8 1177 Hub Oil Seal Through Drum and Both
9 - Keyway (Part of 4010) Wheels
10 - Flange (Part of 4010) 25 - Locating Hole in Inside
Wheel for Hub Pin
11 - Spindle (Part of 4010)
26 - Inside Wheel (Part of 1001)
12 2211 Brake Backing Plate
1107
27 - Locating Pin in Wheel (Not
13 Wheel Stud Used on Outside Wheel)
14 1243 Rear Wheel Bearing Inner 28 - Locating Hole in Outside
Cup Wheel
15 1109 RearHub
(Continued)
ALL RIGHTS RESERVED
I Refer to Section 05-00. 6. Place a drain pan under the axle shaft (4234) and
rear hub (1109). Remove the eight 7 / 16-inch
axle shaft bolts and remove the axle shaft.
Axle Shaft, Rear Hub, Oil Seal and Outer

Wheel Bearing

Locknut Wrench T85T-4252-AH
Removal
1. Set the parking brake and loosen the eight axle
shaft retaining bolts. E9788-A
2. Raise the vehicle to the desired working height,
keeping the axle parallel with the floor.
3. Release parking brake and back off the rear
brake adjustment, if necessary.
4. Remove the wheel (1007).
5. Remove brake drum (1126). Push-on (sheet
metal) drum retainer nuts may be discarded.
Push-on retainer nuts are used for shipping
purposes only and have no effect on vehicle
function.
EM74-1A
ALL RIGHTS RESERVED
~ Axle Shaft Removal
EM71-2A
7. CAUTION: The hub nuts are right-hand

thread (right hub) and left-hand thread (left
hub). Each hub nut is stamped RH for the
right hub nut or LH for the left hub nut.
Install Locknut Wrench T85T-4252-AH so that
the drive tangs of the tool engage the four slots in
the hub nut.
HUB HUB
NUT - - - : . p......~ ASSEMBLY
1109
LOCKNUT r-____ LUAlllo---- DRIVE

TANG
WRENCH
T85T-4252-AH E8602-e
E6501·D
8. CAUTION: A new hub nut must be installed if
used hub nut comes apart during removal or
installation.
CAUTION: Under no circumstances are
power impact tools to be used when
performing these operations.
NOTE: The hub nut will ratchet during this
operation.
Remove hub nut (counterclockwise for right-hand
thread; clockwise for left-hand thread).
ALL RIGHTS RESERVED
9. Install Step Plate Adapter D80L-630-7 or 12. To replace hub oil seal, refer to Rear Hub,
equivalent. Full-Floating Axle Disassembly and Assembly in
this section.
13. NOTE: The rear wheel bearing inner cone and
roller (1244) is located behind the hub oil seal. A
new hub seal must be installed each time the hub
assembly is removed.
CAUTION: Extreme care should be taken not
to scratch or gouge seal or bearing surfaces.
If after hub removal, the hub seal or seal inner
sleeve remains on the spindle, remove it as
shown.
E6503-C
10. Install2-Jaw Puller D80L-1002-L or equivalent

and loosen rear hub to the point of removal.
PRY BAR E9254-A
E6504-C
11. CAUTION: Do not drop outer hub bearing

when removing.
Remove rear hub assembly.
ALL RIGHTS RESERVED
REMOVAL AND INSTALLATION (Con~inued)
14. Inspect seal surface for scratches or damage.

Inspect inner shoulder for damage from bearing
cone turning. Remove all scratches, gouges or
galling damage with No. 600 or finer wet or dry
sandpape~.
COAT SPINDLE WITH

AXLE LUBRICANT ~1A
SEAL SURFACE 4. NOTE: Installing the rear hub in the following

manner causes the hub outer bearing to act as a
pilot, making the installation easier.
Coat the spindle with recommended axle
lubricant. Push rear hub (with hub outer bearing
seated in outer cup) onto spindle.
Rear Hub and Hub Outer Bearing Installa,io"
INNER SHOULDER E9255-A
Installation
1. Clean spindle thoroughly after removing rear hub,
th~ncoat the spindle with axle lubricant.
2. NOTE: Hub bearings must be prelubed with
grease prior to installation. Use Premium
HUB OUTER
Pack each bearing cone and roller with a bearing BEARING
packing tool, using Premium Long-Life Grease 1240
E86G7-B
specification ESA-M 1C75-B.
5. CAUTION: A new hub nut must be installed if
3. Fill the hub cavity with 29.6 ml (1 oz.) of clean hub nut comes apart during installation or
motor oil. removal.
CAUTION: Make sure the hub nut tab is
located in the keyway prior to thread
engagement.
Install the hub nut on the spindle. Turn hub nut
clockwise for right-hand thread,
counterclockwise for left-hand thread.
E9789-A

ALL RIGHTS RESERVED
Hub Nut Installation
FULL FLOAllNG AXLE HUB NUTS
Part Part
1 - Spindle (Part of 4010) 5 - Hub Nut Tab
2 1109 RearHub A - Thread (RH) (Install
3 1A124 Hub Nut Clockwise)
4 - Keyway B - Thread (LH) (Install
Counterclockwise)
(Continued)
6. Install Locknut Wrench T85T-4252-AH on

spindle.

ALL RIGHTS RESERVED
i
7. CAUTION: After tightening hub nut to

specification -- 75-88 N·m (55-65Ib-ft), Part
ratchet back eight teeth or notches on the Item Number Description
hub nut (1/6 turn). Eight clicks must be 3 - Torque Wrench
heard in order to have performed· the A - Tighten to 75-88 N·m
procedure correctly. (55-65 Lb-Ft) Back Off 8
NOTE: The hub nut will ratchet as torque is Clicks
applied.
8. Inspect axle shaft a-ring seal for cracks, nicks or .
Tighten hub nut to 75-88 N·m (55-65Ib-ft). Rotate wear and replace if required.
rear hub occasionally while tightening.
9. Install the axle shaft.
10. Coat the threads of all eight axle shaft retaining
bolts with Loctite@ or equivalent.
11. Install and tighten axle shaft retaining bolts until
they seat.
CAUllON: THIS OPERA11ON PICTURES A RIGHT-

HAND THREAD NUT BEING
nGHTENED. REVERSE THIS
PROCEDURE FOR LEFT-HAND
THREAD NU'T: E8946-C
Part
1 T85T-4252-AH Locknut Wrench
2 1109 Rear Hub
(Continued)

ALL RIGHTS RESERVED
05-02B-9 Wheel Hubs and Bearings, Ford Full-Floating Axle 05-02B·9
Axle Shaft Installation
12. NOTE: Prior to installing brake drum, adjust brake 17. Lower the vehicle.
so that brake diameter is 0.762mm (0.030 inch) 18. Make brake adjustments if necessary.
less than drum diameter.
19. Tighten wheellugnuts to 190 N·m (140 Ib-ft).
CAUTION: Remember, the last step of this
procedure is to tighten the axle shaft bolts to 20. Tighten eight axle shaft retaining bolts to 95-115
specification, after the wheel lugnuts have N·m (70-85 Ib-ft).
been tightened.
Install brake drum.
13. Install wheel and tire.
14. Loosen filler plug. If axle lube begins to seep out,
retighten filler plug. If there is no lubricant
Rear Hub, Full-Floating Axle
seepage, remove filler plug and fill to bottom of
filler plug hole with specified lubricant.
15. Wipe any particles off magnetic fill plug. Description Tool Number
16. Install filler plug and tighten to 21-40 N·m (15-30 Hub Inner Bearing Cup Replacer T85T-1225-BH
Ib-ft). Driver Handle T80T-4000-W
Hub Seal Replacer T93T-1175-AR
Bearing Cup Replacer T75T-1225-A
Disassembly
1. Install rear hub (1109) in soft-jawed vise.
E861'·'B

ALL RIGHTS RESERVED
2. CAUTION: Care must be taken not to damage

hub seal bore with seal removal tool. REAR WHEEL
BEARING
NOTE: The outer retaining ring may be dislodged INNER CONE
during this procedure. If so, remove outer AND ROLLER
1244
retaining ring and the inner seal sleeve and
proceed to remove seal.
Using a ttJin blade screwdriver, pry up seal from
bottom of bore. Then use larger blade to finish
removal.
E861..8
5. CAUTION: Make sure rear hub is

repositioned securely in vise.
Reposition the rear hub in the vise and remove
the rear wheel bearing inner cup with a brass
drift.
3. Remove rear wheel bearing oil slinger.
REAR WHEEL
BEARING
OIL SLINGER INNER CUP
1250 1243
HUB
E8515-B
E9790-A
4. Remove rear wheel bearing inner cone and roller

(1244).

ALL RIGHTS RESERVED
6. Remove the hub outer bearing cup with a brass 7. After the bearing cups have been removed.
drift. thoroughly clean hub bearing cavity and seal bore
with cleaning solvent and dry.
HUB OUTER Assembly
BEARING CUP
1239 1. Place the outer bearing cup in the rear hub.
2. CAUTION: Bearing Cup Replacer must be
held straight during installation to make sure
bearing cup seats properly.
Position Bearing Cup Replacer T75T-1225-A and
Driver Handle T80T-4000-W squarely into rear
hub and strike handle until outer bearing cup is
fully seated.
E8518-B
Outer Bearing Cup Installation
POSITIONING CUP
INSTAWNG OUTER BEARING CUP
HUB OUTER
BEARING CUP
1239
REAR
HUB
1109
E8517-e
3. Place the rear wheel bearing inner cup in the rear

hub.

ALL RIGHTS RESERVED
4. CAUTION: Bearing Cup Replacer must be

held straight during installation to make sure
bearing cup seats properly.
Position Hub Inner Bearing Cup Replacer
T85T-1225-BH and Driver Handle T80T-4000-W
squarely into rear hub and strike handle until inner
bearing cup is seated.
Rear Wheel Bearing Inner Cup Installation
INSTALUNG REAR WHEEL
BEARING INNER CUP
POSmONING CUP
DRIVER
HANDLE
T80T-4000-W
HUB INNER
BEARING CUP
REPLACER
T85T-1225-BH
INNER
BEARING
CUP
1243
E8&18-C
5. CAUTION: Make sure all sharp edges, nicks

and burrs are removed. This step is REMOVE ALL SHARP
important in order to avoid cutting new seal EDGES, NICKS OR BURRS
during installation.
Thoroughly inspect hub seal bore. Clean hub bore
before installing hub inner bearing.
E9791-A

ALL RIGHTS RESERVED
DISASSE~BLYAND ASSEMBLY (Continued)
6. NOTE: Pack each bearing cone and roller

assembly with a bearing packing tool using
ESA-M1C75-B.
Place rear wheel bearing inner cone and roller in
the cup.
REAR WHEEL
BEARING
INNER CONE
AND ROLLER
1244
9. Install hub seal on hub seal replacer

T93T-1175-AR.
E1I1....
7. CAUTION: Do not coat seal bore with grease.

Lightly coat seal bore with clean motor oil.
E9793-A
10. Lightly coat hub seal outer diameter with clean

motor oil.
E9258-A
8. CAUTION: Hub seal must be free of dirt or

grease before installation.
Position oil slinger on bearing cone with tabs
pointing toward bearing. ,...
Install hub seal on Hub Seal Replacer - - E9794-A
T93T-1175-A.

ALL RIGHTS RESERVED
05-02B-14 Wheel Hubs and Bearings, Ford Full-Floating Axle 05·02B·14
11. CAUTION: Install new seal if seal is cocked

during or after installation.
NOTE: Make sure hub is located on a SOLID
SURFACE before attempting to install seal.
Position installer tool with seal on hub.
SPECIFICATIONS
E9795-A
TORQUE SPECIFICATIONS,
FULL-FLOATING AXLE ONLY
12. Insert tool with seal squarely into hub. Hold tool Description N·m Lb-Ft
straight. Strike handle until hub seal is fully
Hub Nut· 75-88 55-65
seateq.
Wheel Lugnut (Both Single and 190 140
Dual Rear Wheel)
Axle Shaft-to-Hub Bolts 90-115 70-85
Filler Plug 21-40 15-30
a Critical torque information after tightening hub nut to
specification, 75-88 N·m (55-65 Ib-ft), ratchet back eight
teeth or notches on the hub nut (1 /6 turn). Eight clicks must
be heard during this operation in order to have performed it
correctly.

Tool Number/
T93T-1175-AR
~TlI3T.117tI-A
Hub Seal Replacer
T80T-4000-W
E9796-A Driver Handle
~
TIOT-4000-W
13. Wipe seal and hub area as shown al1d inspect the
seal inner diameter to make sure it is clean and T85T-4252-AH
that the seal is installed squarely in the bore. Locknut Wrench
~
Apply a ligt,t coat of clean motor oil to the seal
inner diameter before installing the hub assembly
on the spindle.
TUT-42S2-AH
(Continued)

ALL RIGHTS RESERVED

(Continued)

D80L-630-A Step Plate Adapter Set
T85T-1225-BH
D80L-1002-L 2-Jaw Puller Tool
Hub Inner Bearing Cup Replacer
~
TIlT·1221-8H
;
T75T·1225·A
Bearing Cup Replacer
niT·1221-A

ALL RIGHTS RESERVED
05-02C-1 Differential, Limited Slip, Ford 10.25-lnch Ring Gear 05-02C-1
SECTION OS-02C Differential, Limited Slip, Ford

~ 10.2S-lnch Ring Gear
VEHICLE APPLiCATION .....•............................•........05-02C-1 REMOVAL AND INSTALLATION (Cont'd.)
DESCRIPTION AND OPERATION Differential Case •.•........•.•..••......••.•.....••••.•.•.••.••..OS-02C-:I!
Differential, Limited Slip .......•............•.....•......••••.OS-02C-1 DISASSEMBLY AND ASSEMBLY
DIAGNOSIS AND TESTING Differential Case ..•.••..••.•.•••.••.•.••.•.••••••..••.•.••.••.•••05-02C-:3
Differential, Limited Slip •......••.••.....•........•.......•.•.OS-02C-2 SPECiFiCATIONS...••......•.........••.••....•••••.••.•.....••.••OS-Q2C-11
REMOVAL AND INSTALLATION SPECIAL SERVICE TOOLS/EQUIPMENT ......•.•••.....OS-Q2C-11
Differential Bearings ......•................•••..........•..•.•.OS-02C-2
VEHICLE APPLICATION
F-250, F-350 Equipped with Ford 10.25-lnch Ring
Gear Axle and Limited Slip Differential
Differential, Limited Slip The Limited Slip differential has the same power flow
as a conventional differential, plus a more direct flow
The Ford Limited Slip differential option is available on
that automatically takes effect as driving conditions
F-250-350 vehicles with 10.25-inch ring gear rear
demand. This more direct flow is from the differential
axles.
case to each axle shaft through a clutch plate and disc
The Limited Slip assembly, except for the differential arrangement. Arrangement of these plates and discs
case (4204) and its internal components, is identical to is at the option of the vehicle manufacturer, so care
the conventional rear axle (4001). The Limited Slip should be taken during disassembly to note the
differential (4026) employs two differential clutch arrangement of these components.
packs to control differential action. The side gear
In diagnosis of vehicie operators' complaints, two
mounting distance is controlled by 10 clutch plates and
things should be recognized:
one Belleville spring plate. The differential clutch pack
consists of two plate designs: a splined clutch plate • If, with unequal traction, both wheels slip, the
that engages the splines of the side gear hub, and Limited Slip has done all it can possibly do.
alternate-tabbed or stationary clutch plates.
• In extreme cases of differences in traction, the
The Limited Slip differential is similar to a conventional wheel with the least traction may spin after
differential, except part of the torque from the ring limited-slip has transferred as much torque as
gear is transmitted through differential clutch packs possible to the non-slipping wheel.
between the differential side gears (4236) and
differential case. The differential clutch packs are
engaged by a preload from dished springs and
separating forces from the axle shafts (4234). This
occurs as torque is applied through the ring gear.
A conventional differential transmits all of the ring rear
torque through the differential side gears to the axle
shafts. Torque is at all times equal on the axle shafts
and if one wheel slips, the other wheel can only put out
as much torque as the slipping wheel.

ALL RIGHTS RESERVED
Each differential clutch pack is premeasured for NOTE: It is not necessary to remove the differential
proper stack height. Do not separate differential bearings (4221) as a part of the differential case
clutch packs and intermix the clutch plates and clutch disassembly procedure.
discs from the differential clutch packs.
Removal
UMITED sUP DlFFERENnAL-eUTAWAY YEW 1. Mount the differential case (4204) in a vise. Use
brass pads on vise jaws to prevent damage.
Mount split-type pinion bearing cone remover on
the differential case. lighten bolts on puller to
separate the bearing cone from the case face.
SPLIT-TYPE PINION BEARING

CONE REMOVER
EM1O-S
Part 2. Place step plate on bearing inner cone. Apply a

Item Number Description small amount of grease to the step plate bore.
1 4215 Differential Pinion Gear
2 4880 Differential Clutch Pack
3 4236 Differential Side Gear STEP PLATE
4 4241 Differential Pinion Shaft Lock D8OL-630-7
Bolt OR EaUIVALENT
5 4880 Differential Clutch Pack
6 4211 Differential Pinion Shaft
Differential, Limited Slip

Differential Case
Refer to Section 05-02A.
3. CAUTION: It is extremely important to apply

Differential Bearings a liberal amount of 011 to the screw threads of
remover /replacer.
Mount push-type remover / replacer on the
De8crlptlon Tool Number bearing cone remover, making sure that the
remover / replacer shaft seats in the bore of the
Front Hub Remover / Replacer T81P-1104-C
step plate. Pull the differential bearing off the
differential case.

ALL RIGHTS RESERVED
4. Replace differential bearings whenever they are

removed from the differential (4026).
1'4--- PRESS RAM

DIFFERENTIAL
BEARING CONE
REPLACER --~
D81T-4221-A
DIFFERNETIAL
BEARING-4221
E6001-E
Differential Case
Installation Description Tool Number
1. NOTE: When performing the following, press Limited Slip Differential Rotating Tool T86T-4205-A
against the differential bearing cone only.
Install differential bearings on the case hubs using
Differential Bearing Cone Replacer 081 T-4221-A
or equivalent.

ALL RIGHTS RESERVED
Disassembly
NOTE: The differential bearings (4221) need not be
removed to overhaul the Ford Limited Slip differential.
If bearing removal is required, refer to Differential
Bearings, Removal and Installation in this section.
Differential Case
E6412·F
Part Part
1 4A323 Retainer Clips 7 4215 Differential Pinion Gears
2 4211 Differential Pinion Shaft 8 - Dished Spacer
3 4204 Differential Case (Part of 4880)
4 4236 Differential Side Gear 9 4880 Clutch Pack
5 4241 Differential Pinion Shaft Lock 10 - Clutch Disk (Part of 4880)
Bolt 11 - Clutch Plate (Part of 4880)
6 4230 Differential Pinion Thrust
Washer
(Continued)

ALL RIGHTS RESERVED
1. Remove the differential pinion shaft lock bolt.
E6416-e
4. Install Step Plate D83T-4205-C2 (from

D83T-4205-C) or equivalent in botfom side gear
bore. Apply a small amount of grease to centering
hole of the step plate.
E6414-C
2. Install Limited Slip Differential Tool D83T-4205-A

or equivalent in a suitable vise. Install differential
(4026) in the vise with the ring gear side facing
up.
LIMITED SLIP
DIFFERENTIAL
TOOL-D83T4205-A
STEP PLATE
D83T-4205-C2
E6417-C
E6415-C
3. With a hammer and drift, drive the differential

pinion shaft (4211) from the differential case
(4204).

ALL RIGHTS RESERVED
05-02c-e Differential, Limited Slip, Ford 10.25-lnch Ring Gear 05-02c-e
5. Install nut in upper differential side gear (4236).

Hold nut in position while installing hex screw.
Tighten hex-head screw until contact is made
with the step plate.
NUT
D83T-4205-C1
E6419-C
7. With an appropriate size feeler gauge, push the

differential pinion thrust washers (4230) out from
E6418-C
between the pinion gears and the differential
case. Remove the differential pinion thrust
washers, then back off the forcing screw until it is
6. Insert dowel bar in hole of nut. Tighten forcing loose (approximately one turn).
screw to force differential side gear away from
the differential pinion gears (4215). The dowel
bar is used to keep the nut from turning when the
forcing screw is tightened.
DIFFERENTIAL
PINION GEAR
4215
i\ II it (i E6420-C
8. WARNING: KEEP FINGERS/HANDS AWAY

FROM PINION GEARS WHEN ROTATING
DIFFERENTIAL CASE WITH DIFFERENTIAL
ROTATING TOOL.
Insert Limited Slip Differential Rotating Tool
T86T-4205-A in the pinion shaft bore and turn the
differential case to "walk" the differential pinion
gears out to the differential case windows.

ALL RIGHTS RESERVED
9. Remove the differential pinion gears. Assembly

1. Prelubricate each clutch disc and clutch plate
with Additive Friction Modifier F3TZ-19B546-MA
LIMITED SLIP or equivalent meeting Ford specification
DIFFERENTIAL ROTATING WSP-M2C 196-A.
TOOL-T86T-4205-A
=
DIFFERENTIAL
CASIfiE
4204
rr
DIFFERENTIAL
PINION
GEAR
4215 E6421·D
10. Remove the forcing screw and step plates.

Remove the differential side gears, retainer clips 2. Prelubricate the thrust face of the differential side
and and differential clutch packs. gears. Assemble the clutch plates and clutch
discs to the side gear splines in exactly the same
11. CAUTION: When separating the clutch plates sequence in which they were removed. Assemble
and clutch discs, note the sequence in which the retainer clips to the ears of the clutch plates.
they are disassembled. They must be Make sure both clips are completely assembled
reassembled in the same sequence. and seated onto the ears of the clutch plates.
Remove the retainer clips from both differential
clutch packs to allow separation of the clutch
discs and clutch plates for cleaning and
inspection. Refer to the exploded view at the
beginning of this procedure.
E6422·D
ALL RIGHTS RESERVED
OS-02C-8 Differential, Limited Slip, Ford 10.2S-lnch Ring Gear OS-02C-8
Side Gear, Clutch Plates and Discs
E6424-E
Part Part
1 4236 Differential Side Gear 3 - Clutch Disc (Part of 4880)
2 - Dished Spacer 4 - Clutch Plate (Part of 4880)
(Part of 4880)
(Continued)
3. Install holding tool D83T-4205-A or equivalent in a 4. Position step plate in the bottom side gear bore.
suitable vise. Place differential case on holding Apply a small amount of grease to the step plate
tool with ring gear side facing up. Insert the bore. Position nut in the top side gear bore and
differential clutch packs and differential side hold it in place. Install the hex-head screw and
gears into the differential case. Make sure the tighten it two turns after it contacts the bottom
differential clutch packs stay assembled to the step plate. Insert the dowel bar in nut bore to
side gear splines and that the retainer clips are keep the nut from turning as the hex screw is
completely seated in the pockets of the tightened.
differential case. Hold the upper clutch pack and
side gear assembly in place to prevent it from
falling out of the differential case.
DIFFERENTAIL
CLUTCH PACK
AND
DIFFERENTIAL
SIDE GEAR NUT
4236 D83T-4205-C 1
E6426-D
E6425·C
ALL RIGHTS RESERVED
5. Position the differential pinion gears in the window

of the differential case so that they mesh with the
differential side gear teeth. Hold the differential
pinion gears in place. Make sure that the
differential pinion gears are -180 degrees apart so
they will correctly align with the pinion shaft bore.
=--
E&a7-8
6. NOTE: It will probably be necessary to loosen or

tighten the forcing screw to allow the differential
pinion gears and differential side gears to rotate.
WARNING: KEEP FINGERS/HANDS AWAY
FROM PINION GEARS WHEN ROTATING
DIFFERENTIAL CASE WITH DIFFERENTIAL
ROTATING TOOL.
Insert the rotating handle into the pinion shaft
bore and turn the differential case. This will cause
the differential pinion gears to engage the
differential side gears and ··walk" into the
differential case. Rotate the differential case until
the pinion mating shaft holes are lined up exactly
with the holes in the differential pinion gears.
ALL RIGHTS RESERVED
7. Prelubricate both sides of the differential pinion 9. Loosen the forcing screw and remove the step
thrust washers with Rear Axle Lubricant Gear plate and nut from the side gear bores. Install the
Lubricant EOAZ-19580-AA or equivalent meeting differential pinion shaft in the differential case.
Ford specification ESP-M2C 154-A. Apply torque Install the pinion lock bolt and tighten to 20-40
to the forcing screw to allow clearance to insert N·m (15-30 Ib-ft).
the differential pinion thrust washers. Insert the 10. If removed, install the ring gear on the differential
differential pinion thrust washers between the case and tighten the attaching bolts to 136-163
differential pinion gears and the differential case N·m (100-120 Ib-ft).
with the concave side facing in.
DIFFERENTIAL
PINION SHAFT
4211
L----~--~
E6431-D
E6429-B
8. Be sure to align the thrust washer holes with the

bore in the differential case PRIOR to installing
differential pinion shaft.
EM30-8
ALL RIGHTS RESERVED
SPECIFICATIONS
LUBRICANT CAPACITIES AND CHECKING PROCEDURES (INTEGRAL REAR AXLE DIFFERENTIAL CARRIER)
Approximate Lubricant Capacity (In-Vehicle Repair) .b
Vehicle Axle U.S. Pints Imperial Pints Liters
F-250, F-350 Regular & Chassis 10.25-lnch Ring Gear 6.5ed 5.4 3.0
CAB, F-250, F-350 H.D.
a Ford design conventional axles use Rear Axle Lubricant XV-80W90-QL or equivalent meeting Ford specification WSP-M2C 194-A.
b Service refill capacities are determined by filling the axle with the specified lubricant to the bottom of the filler hole with the vehicle in
running position.
c Plus 4 oz. (U.S. measure) additive friction modifier, F3TZ-19B546-MA or equivalent meeting Ford specification WSP-M2C196-A for
Limited Slip applications.
d Rear axle lube quantities must be replaced every 160000 km (100,000 miles) or if the axle has been submerged in water. Otherwise, the
lube should not be checked or changed unless a leak is suspected or repair required.
NOTE: 6.5 pints of lubricant is the fill specification when the axle is installed in the vehicle. If the axle is out of the'
vehicle, fill with 7.5 pints of specified lubricant.
TORQUE SPECIFICATIONS (INTEGRAL CARRIER) SPECIAL SERVICE TOOLS DESIRED

Description N·m Lb-Ft Tool Number Description
Differential Bearing Cap Bolt 109-129 80-95 D81T-4221-A Differential Bearing Cone Replacer
Differential Pinion Shaft Lock Bolt 20-40 15-30 D83T-4205-A Limited Slip Differential Tool
Using Loctite@ EOAZ-19554-B D83T-4205-C 1 Forcing Screw and Nut
or Equivalent D83T-4205-C2 Step Plate
Ring Gear Attaching Bolts Using 136-163 100-120 D83T-4205-C3 Driver Handle
or Equivalent
Rear Cover Screw 38-52 28-38
Ratio Tag Hold-Down Bolt 24-38 18-28
Driveshaft to Axle Companion 11-20 8-15
Flange (U-Bolt Nut)
Axle Vent 20 15
Wheel Lugnut (Both Single and 190 140
Dual Rear Wheel)
Rear Anti-Lock Brake System 34-40 25-30
Sensor Bolt

Tool Number /
T86T-4205-A
~~
Limited Slip Differential
Rotating Tool
T81P-1104-C
~
Front Hub Remover I Replacer
T81P-1104-C
ALL RIGHTS RESERVED
05-020-1 Axle, Rear, Dana 05-020-1
SECTION 05·020 Axle, Rear, Dana

VEHICLE APPLICATION ........•.•.••....................•.....•..05-020-1 DISASSEMBLY AND ASSEMBLY (Cont'd.)
DESCRIPTION AND OPERATION Differential Case Removal ....•.....•......•............•.05-02D-6
Axle, Rear, Dana .....•...•....................•............•......05-02D-1 Drive Pinion Removal ...•...•........•........••.......•....05-02D-9
DIAGNOSIS AND TESTING Pinion Bearing Cup Removal..•...•..................•.05-02D-11
Axle, Rear Dana ......•.•..••.......•.•.................•..•.•.....05-02D-3 CLEANING AND INSPECTION
REMOVAL AND INSTALLATION Inspection After Disassembly ...•..•.•.............•.....05-02D-23
Axle Shaft, Rear••.•..•.........................•................•.05-02D-6 Bearing Cups .......•....•................•.................•.05-02D-23
Axle, Rear ..•...•••.......•........................•.................05-02D-6 Carrier Housing ...•..............•..........................•05-020-24
Drive Pinion Seal •.........•.....•..•........................••...05-02D-3 Companion (Universal Joint) Flange ..............•05-o2D-23
Oil Seal and Wheel Bearing ...........•.........•............05-o2D-6 Cone and Roller Assemblies 05-02D-23
DISASSEMBLY AND ASSEMBLY Differential Case .•..........•....•................•........•05-02D-24
Assembly of Differential into Housing .........•......05-02D-21 Gears•...........•.•..•..•.............•.................•..•..•..05-02D-24
Axle Assembly..•......••........•.......................•.......05-o2D-13 Speed Sensor Ring •......................•..•.........•....05-02D-24
Differential Case Assembly ..•..•......................05-02D-13 Inspection Before Disassembly ....•...................•05.02D.23
Differential Case End Play Check 05-02D-15 ADJUSTMENTS
Pinion Bearing Cup Installation .•.....•........•......05-02D-17 Ring Gear and Pinion Backlash ........•........•....•...05-o2D-24
Pinion Position Shim Selection .....••...•..•.•.......05-02D-18 Ring Gear and Pinion Tooth Pattern
Pinion Ring Gear Variation Number •...........•.••.05-02D-16 Interpretation •........•....................•.•....•....•.....05-o2D-26
Axle Disassembly .••.....••.•.....••..••.......•...........•.....05-o2D-6 SPECiFiCATIONS.........•.........•..••.•.....•..........•......•05-o2D-27
Differential Case Disassembly...••.•...............•..•05-02D-8 SPECIAL SERVICE TOOLS/EQUIPMENT ....•....•••....05-o2D-28
VEHICLE APPLICATION
F-Super Duty
Axle, Rear, Dana

Model 80 rear axles (4001) are equipped with
full-floating axle shafts (4234), meaning loads are
supported by the axle housing. These rear axles have
an integral-type axle housing, hypoid gear design with
the centerline of the pinion set below the centerline of
the ring gear. The axle shaft is retained by bolts
attached to the rear hub (1109). The rear hub rides on
two bearings at the outboard end. The axle housing
consists of a cast center section with two steel tubes.
A stamped axle housing cover (4033) uses silicone
rubber or equivalent as a gasket. A metal tag,
attached to axle housing by two cover bolts, is
stamped with the gear ratio and part numbers.
Rear Axle, Dana Model 80 Full-Floating
E9718-A
ALL RIGHTS RESERVED
05-020-2 Axle, Rear, Dana 05-020-2
~ Full-Floating Axle, Model 80
Part Part
1 N808133 Bolt 10 354845 Locknut
2 4234 Axle Shaft 11 4667 Thrust Washer
3 1001 Hub / Shaft Gasket 12 4616 Drive Pinion Bearing Cup,
4 2C190 Rear Brake Anti-Lock Outer
Sensor Location 13 4010 Axle Housing
5 4067 Drive Pinion Preload Bearing 14 4109 Drive Pinion Position Shim
Shim 15 4616 Drive Pinion Bearing Cup
6 4630 Differential Pinion Bearing Inner Cone and Roller
Cone and Roller, Outer 16 4621 Differential Pinion Bearing
7 4676 Drive Pinion Seal 17 4209 Pinion (Matched Set)
8 4851 Rear Axle Companion 18 4209 Ring Gear (Matched Set)
(Universal Joint) Flange and 19 - Identification Tag
Dust Slinger (Part of 4002)
9 4239 Washer
(Continued)
(Continued)
1995 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain. Drivetrain July 1994
ALL RIGHTS RESERVED
05-020-3 Axle, Rear, Dana 05-02D-3
Part Part
20 4241 Differential Pinion Shaft Lock 32 4228 Differential Side Gear Thrust
Pin Washer
21 353051 Fill Plug 33 4236 Differential Side Gear
22 4033 Axle Housing Cover 34 4215 Differential Pinion Gear
23 4346 Screw, Cover 35 4236 Differential Side Gear
24 - Brake Line Clip 36 4228 Differential Side Gear Thrust
(Part of 4033) Washer
25 355765-S Bearing Cap Bolt 37 4067 Differential Bearing Shim
26 - Bearing Cap (Part of 4010) (Preload / Backlash)
27 4222 Differential Bearing Cup 38 4558 Rear Axle Differential Ring
28 4K067 Outboard Spacer Gear Bolt
29 4221 Differential Bearing 39 4204 Differential Case
30 4211 Differential Pinion Shaft 40 4B409 Anti-Lock Speed Sensor
Ring
31 4230 Differential Pinion Thrust
Washer
(Continued)
Axle, Rear Dana COMPANION

Refer to Section 05-00. FLANGE
4851
Drive Pinion Seal

Companion Flange Remover T65L-4851-B
Slide Hammer T50T-100-A
Pinion Seal Replacer T83T-4676-A
Pinion Oil Seal Replacer T88T-4676-A
Removal
The rear axle drive pinion seal (4676) can be replaced DRIVESHAFT
without removing the rear axle assembly (4006) from 4602
E7491-e
the vehicle.
1. Raise the vehicle on a hoist or raise the rear end
of the vehicle with a jack. Install safety stands
under the frame rails and lower the jack or hoist
far enough to allow the rear axle (4001) to drop
into the rebound position for working clearance.
2. NOTE: Note and mark driveshaft / companion
flange position so that it can be reassembled in
the same position to minimize driveline vibration.
Remove the straps and bolts which are threaded
into the companion (universal joint) flange. Wire
the driveshaft (4602) to the frame.
ALL RIGHTS RESERVED
05-020-4 Axle, Rear, Dana 05-020-4
3. NOTE: The pinion nut requires 597-677 N·m 5. Using Seal Remover TOOL-1175-AC or
(440-500 Ib-ft) of torque to remove. equivalent in combination with Slide Hammer
T50T-100-A, remove the pinion seal.
Using Companion Flange Holding Tool
T57T-4851-8 to hold the companion flange, Installation
remove the differential pinion shaft nut.
may result in early seal failure. If pinion seal
becomes cocked during installation, remove
and install new one. Use care to assure the
garter spring remains in place during
a~sembly. If the spring is dislodged, the
pinion seal must be replaced.
Clean the pinion seal seat. Coat the sealing edge
of the new seal with a small amount of hypoid
gear lubricant or equivalent meeting Ford
specification WSP-M2C 197-A. Drive the pinion
seal into the housing using Pinion Seal Replacer
T88T-4676-A.
PINION SEAL
REPLACER
T88T-4676-A
E7495-E
4. Using Companion Flange Remover T65L-4851-8

or 2-Jaw Puller D80L-1002-L or equivalent,
remove the companion (universal joint) flange.
2-JAW COMPANION
PULLER FLANGE
D80l-1 002-L 4851
E7494·D
1995 F'-150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain July 199~

ALL RIGHTS RESERVED
05-020-5 Axle, Rear, Dana 05-020-5
2. NOTE: The rear axle companion flange must

never be hammered on or installed with power
tools.
Coat the inside of the companion flange with a
small quantity of hypoid gear lubricant or
WSP-M2C 197-A and install the flange on the
drive pinion shaft using Companion Flange
Replacer T88T-4851-B.
E7495-E
4. Connect the driveshaft to the companion flange

as originally positioned. Secure with straps and
bolts and tighten to specifications listed at the
end of this section.
COMPANION
FLANGE
4851
PINION
VIEW A
E7492-C
3. Install the pinion attaching nut on the pinion stem

and tighten to 597-677 N·m (440-500 Ib-ft). Hold
the companion flange with Companion Flange
Holding Tool T57T-4851-B while tightening the
nut.
DRIVESHAFT
4602
E7491-C
5. Raise the vehicle, remove the safety stands and

then lower the vehicle to road position. Check the
level of axle lubricant and add the specified
lubricant as necessary.

ALL RIGHTS RESERVED
05-020-6 Axle, Rear, Dana 05-020-6
Axle, Rear 7. Remove safety stands. Lower the vehicle to the

floor.
Removal
1. NOTE: Axle shafts (4234), rear hubs (1109),
rear wheel bearings and the inner wheel bearing
oil seals can be replaced, lubricated or adjusted
without removing the differential (4026) from the
rear axle housing (4010) or the rear axle
assembly (4006) from the vehicle. Refer to
Section 05-02E.
Loosen the wheel stud nuts.
2. Disconnect the shock absorbers (18080) from
the rear axle (4001), and unclamp the rear
stabilizer bar (5A772) if so equipped. Refer to
Section 04-02. Then raise the rear end of the
vehicle frame until the weight is off the rear AXLE
HOUSING
springs (5560). Place safety stands under the VENT
frame (5005) in this' position. 4022
11-24 N·m
3. Disconnect the rear brake hose (2282) and rear (8-18 FT-LB)
E8809-C
axle vent hose at the frame.
4. Disconnect the driveshaft (4602) from the rear
companion (U-joint) flange. Disconnect anti-lock
speed sensor connector and height sensing
brake load sensor proportioning valve linkage. Axle Shaft, Rear
Refer to Section 06-06. Refer to Section 05-02E.
5. Remove the nuts from the rear spring U-bolts, and
remove the rear spring caps. Refer to Section
04-02.
6. Roll the rear axle from under the vehicle, and Oil Seal and Wheel Bearing
drain the lubricant. Remove the wheels. Mount Refer to Section 05-02E.
the rear axle in a work stand. To remove axle
shafts, rear hubs or hub and rotor assemblies,
refer to Section 05-02E. To service differential,
refer to Disassembly and Assembly in this
section.
Axle Disassembly
Installation
1. After installing the rear wheels, roll the rear axle SPECIAL SERVICE TOOL(S) REQUIRED
assembly under the vehicle.
2. Install the rear spring U-bolts and spring caps.
Tighten nuts to 272-368 N·m (200-270 Ib-ft). Companion Flange Holding Tool T57T-4851-B
Pinion Shaft Thread Protector T85T-4209-AH
3. Connect the shock absorbers, and install the rear
Bearing Cup Replacer T77F-1102-A
stabilizer bar in position. Tighten shock absorber
to 300-405 N·m (220-300 Ib-ft). Tighten stabilizer
bar bolts to 37-50 N·m (27-37Ib-ft)~ Outer Pinion Bearing Cup Remover T88T-4628-A
4. Connect the driveshaft to the rear axle Differential Case Removal

companion (universal joint) flange. Refer to
Section 05-01 for installation instructions and 1. Remove the rear axle (4001) from the vehicle.
torque specifications. Connect anti-lock speed Refer to Axle, Rear, Removal and Installation in
sensor connector. this section.
5. Connect the rear brake hose at the frame and 2. Remove axle housing cover plate screws and
bleed the brakes. The rear axle vent hose is part axle housing cover (4033). Tip carrier to allow
of the rear brake hose and uses a special "flow" lube to drain completely. Clean the cover face of
bolt to secure the hose block to the rear axle. the carrier, making sure it is free from any nicks.
Connect hose at frame. Remove old RTV gasket material.
6. Fill the rear axle with the proper grade and
specified amount of axle lubricant or equivalent
meeting Ford specification WSP-M2C197-A. This
is a different lube than that used in Ford rear
axles.

ALL RIGHTS RESERVED
05-020-7 Axle, Rear, Dana 05-020-7
3. CAUTION: Before removing differential case 6. Mark or tag differential bearing cups (4222)
(4204) and ring gear, pull axle shafts (4234) indicating from which side they were removed.
out far enough for clearance to remove
differential (4026). Refer to Section 05-02E.
NOTE: Mating letters are stamped on rear axle
bearing retaining caps and carrier. Letters are in
vertical and horizontal positions. Note the
positions of letters before removal. Matching
letters is important at time of assembly.
Remove rear axle bearing retaining caps.
BEARING CAPS
Part
1 TOOL-4000-E Differential Housing
Spreader Tool
2 - Ring Gear (Part of 4209)
MATING Right-Hand Spacer
3 4K067
LETTERS E8552·B
4 4K067 Left-Hand Spacer
4. Place Differential Housing Spread€:: 5 - Pry Bars
TOOL-4000-E or equivalent on the rear axle 7. The rear axle has spacers installed outboard of
housing (4010). Install Dial Indicator / Magnetic
each differential bearing cup. Remove both
Base D78P-4201-B or equivalent on the rear axle spacers and tag each indicating the side each
housing. Do not spread axle housing more than was removed from. Inspect both spacers for
0.38mm (0.015 inch). damage, bent or grooved conditions. Replace if
required.
DIAL INDICATOR!
MAGNETIC BASE
D78P-4201-B DIFFERENTIAL
HOUSING SPREADER
TOOL-4000-E
E7674-D
5. NOTE: Use caution to avoid damage to ring gear.

Pry differential case from carrier with two pry
bars. After differential case has been removed,
remove spreader.

ALL RIGHTS RESERVED
05-020-8 Axle, Rear, Dana 05-020-8
Differential Case Disassembly 5. Tap each bolt head alternately with a rawhide
hammer to loosen the ring gear. Remove bolts
1. NOTE: Differential bearing shims (4067) are
and ring gear.
available in thicknesses of .08, .13, .25 and
.76mm (.003, .005, .010 and .030 inch).
RAWHIDE
Remove differential bearings with Pinion and OR PLASTIC
Carrier Bearing Puller D81L-4220-A or HAMMER
equivalent. Place the tool in a vise when removing
bearing. Wire differential bearing shims,
differential bearing cup, bearing cone, and
\
outboard spacer together. Identify from which DIFFERENTIAL
side they were removed (ring gear side or CASE
opposite side). If differential bearing shims are 4204
damaged, replace with new ones.
2. Reposition differential case in puller and remove
other bearing cone as described above. Replace
bearings whenever removed from the carrier.
PINION AND CARRIER

BEARING PULLER
081 L-4220-A
RING
GEAR
E7498·D
6. If required, remove the speed sensor ring with a

soft-faced hammer. Discard the speed sensor
ring.
E8553-B
3. Place a few shop towels over the vise to prevent

the teeth of ring gears from being nicked. Place
differential case in vise.
4. NOTE: Whenever removing the ring gear bolts,
SPEED SENSOR
always replace with new bolts upon assembly. RING
Use grade 9 bolts for service replacement for all 48409
Dana rear axles. E9720-A
CAUTION: Use care to not damage speed
sensor ring when removing ring gear. If the
speed sensor ring is removed, it must be
replaced with a new one.
Remove bolts on ring gears. Leave four bolts
loosely assembled 90 degrees apart.
1995 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drive~rain July 1994

ALL RIGHTS RESERVED
05-020-9 Axle, Rear, Dana 05-020-9
7. Replace differential case in vise. Use a small drift 10. Remove differential pinion gears and differential
to drive out differential pinion shaft lock pin pinion thrust washers (4230) behind the
(4241) which secures the differential pinion shaft differential pinion gears.
(4211). 11. Lift out differential side gears and differential side
gear thrust washers (4228).
12. Inspect all parts, including the machined surfaces
of the differential case itself. If excessive wear is
visible on all parts, the complete differential
should be replaced. If anyone of ~he gears is to
be replaced, replace as a set.
8. Remove differential pinion shaft with drift as

shown.
DIFFERENTIAL
PINION SHAFT
DIFFERENTIAL
4211
SIDE GEAR
4236
E6347-8
Drive Pinion Removal

WARNING: HANDLE PINION GEAR CAREFULLY TO
PREVENT INJURY.
On the spline end of the pinion, there are pinion shims.
These pinion shims may stick to the pinion or bearing
or even fall out. These pinion shims are to be collected
and kept together for reassembly. Try not to damage
pinion shims. If drive pinion shims are damaged,
E6672-B replace with new ones. Refer to Pinion Shims chart
under Pinion Position Shim Selection in this section.
9. To remove differential side gears (4236) and
differential pinion gears (4215) rotate the
differential side gears. The differential pinion
gears will turn to the opening of the differential
case.

ALL RIGHTS RESERVED
05·020·10 Axle, Rear, Dana 05-020-10
CAUTION: The pinion shim assembly sequence

must be followed. If sequence is not followed and
components are improperly assembled, it may
cause unit failure. Refer to the following
illustration.
Drive Pinion Assembly
10
E9721-A
Part Part
1 - Drive Pinion (Part of 4209) 7 390313-5100 Pinion Nut
2 4663 Drive Pinion Bearing Preload 8 4851 Companion (Universal Joint)
Adjustment Shim Flange
3 4616 Pinion Bearing Cup, Outer 9 4676· Pinion Seal
4 4670 Bearing Thrust Washer 10 4630 Rear Drive Outer Pinion
5 4859 Dust Shield Bearing Cone and Roller
6 1124 Drive Pinion Nut Locking
Washer
(Continued)

ALL RIGHTS RESERVED
05-020-11 Axle, Rear, Dana 05-020-11
1. NOTE: Pinion nut requires 597-677 N·m (440-500

Ib-ft) of torque to remove.
Turn nose of carrier in a horizontal position and
remove pinion nut. Hold pinion flange with
and remove pinion nut and drive pinion nut locking
washer.
PINION SHAFT
THREAD
PROTECTOR
T85T-4209-AH
E5874-1A
Pinion Bearing Cup Removal

1. Pull out pinion seal with Bearing Cup Replacer (Oil
Seal Replacer) T77F-1102-A, and Impact Slide
Hammer T50T-1 OO-A. Discard pinion seal.
REPLACE WITH NEW ONE AT TIME OF
ASSEMBLY. Remove differential pinion bearing
(4630) and drive pinion shaft bearing thrust
washer.
SLIDE HAMMER
T50T-100-A
E8083-C
2. Remove companion (universal joint) flange with

2-Jaw Puller Tool D80L-1002-L or equivalent.
Replace pinion seal if companion (universal joint)
flange shows signs of wear.
2-JAW COMPANION
PULLER FLANGE
D80l-1 002-l 4851
PINION
SEAL
4676
E7494-D E4834-C
3. Remove pinion by tapping with a rawhide hammer

and Pinion Shaft Thread Protector
T85T-4209-AH. Catch the pinion with your hand
to prevent from falling and being damaged.

ALL RIGHTS RESERVED
05-02D-12 Axle, Rear, Dana 05-020-12
CAUTION: Do not nick bore of carrier. Bearing Cup Removal

2. NOTE: The front and rear section of carrier may
vary in pinion bore depth due to the need for .
either a baffle or oil slinger or both. The baffle
serves the same purpose as a dam, to maintain
pinion bearings with lubricant. The oil slinger 3
serves the purpose of assisting the lube to flow
up through the oil channels to lubric~te the pinion
bearings. If used, they are part of the pinion
setting adjustment.
Turn nose of carrier down. Remove outer
differential bearing cup with Driver Handle
D81L-4000-A or equivalent and the correct size
bearing cup remover as shown in the following
illustration.
3. NOTE: Drive pinion bearing adjustment shims
(4663) are located between the differential drive
pinion bearing cup (4616) and bore of carrier and
may also include an Qil baffle. If pinion shims an~
baffles are bent or'nicked, replace at time of
asserT1bly. Wire pinion shims may stack together;
if so, measure stacks. If stack has to be
replaced, replace with pinion shim of same
thickness.
Remove the inner differential bearing cup with OUTER CUP REMOVAL
Driv~r Handle 081 L-4000-A or equivalent and the
correct size bearing cup remover as shown in the
fol~owing illustration.
INNER CUP REMOVAL

E9722·A
Part
1 081T-4628-B Pinion Bearing Cup Remover
(Inner)
2 T88T-4628-A Pinion Bearing Cup Remover
(Outer)
3 D1L-4000-A Driver Handle
4 4616 Differential Drive Pinion
Bearing Cup

ALL RIGHTS RESERVED
05-020-13 Axle, Rear, Dana 05-020-13
2. Install both differential side gears. Apply grease

to the new differential pinion thrust washers
(4230) and the new differential pinion gears
(4215).
3. NOTE: An easy way to assemble the differential
side gears and differential pinion gears is to have
OIL SLINGER
4670 all parts lubricated with rear axle lubricant
OIL meeting Ford specification WSP-M2C 197-A
BAFFLE
before assembly.
Assemble both differential side gears and
differential side gear thrust washers, hold in place
with hand, then assemble the differential pinion
gears and differential pinion thrust washers to
E7115-B hold the differential side gears in place.
4. Rotate the differential side gears until the holes of
4. NOTE: Both baffle and oil slinger are part of the
the washers and pinion gears line up with the
pinion shims and are to be kept intact for
holes of the differential case. If the differential
assembly.
pinion gears cannot be rotated by hand, install
Remove differential pinion bearing from pinion one of the axle shafts (4234) into the spline of
with Pinion and Carrier Bearing Puller differential side gear and use a pipe wrench to
081 L-4220-A or equivalent. turn the axle shaft.
PINION AND CARRIER

BEARING PULLER
081 L-4220-A
E4847-B
PINION GEAR
4215
Axle Assembly E6350-B

Differential Case Assembly
5. Use a drift to line up the holes with those of the
1. Place differential case (4204) in vise. Apply differential case.
ESA-M 1C75-B to new differential side gear thrust
washers (4228) and to rearhubs(1109)and
thrust face of the new differential side gears
(4236).

ALL RIGHTS RESERVED
05-020-14 Axle, Rear, Dana 05-020-14
6. Assemble drive pinion shaft and drive on SPEED SENSOR

differential pinion shaft (4211) to remove drift. RING
Align lock pin hole of the differential pinion shaft 48409
with the lock pin hole of the differential case.
DRIFT
DIFFERENTIAL
PINION SHAFT
4211
RING GEAR
4209
...
VIEW A
SPEED SENSOR
RING TAB
E6401-B
7. Assemble differential pinion shaft lock pin (4241).

Peen metal of differential case over pin in two
places 180 degrees apart to lock in place. Note
the location of the slot in the differential pinion
shaft lock pin and peen 90 degrees away.
VIEW A
E9723-A
9. Press the speed sensor ring on the differential

case. The differential case flange acts as a pilot
for the speed sensor ring. Apply Thread Lock and
Sealer EOAZ-19554-AA or equivalent meeting
Ford specification WSK-M2G315-A5 (TYPE II) to
new ring gear bolts.
SPEED SENSOR
RING
48409
PEEN
90 DEGREES
EITHER SIDE
FROM SLOT IN
ROLL PIN
PIN
\\
E6402·C
~
TAB ~~
8. CAUTION: Tab on speed sensor ring must be AND~·
aligned with slot in differential case. SLOT E9724-A
Align tab in speed sensor ring with slot in
differential case. Start two ring gear bolts through 10. Draw up ring gear bolts alternately and evenly.
the differential case into the ring gear to make Tighten ring gear bolts to 272-325 N·m (200-240
sure differential case and ring gear bolt hole align. Ib-ft).

ALL RIGHTS RESERVED
05-020-15 Axle, Rear, Dana 05-020-15
Differential Case End Play Check

1. Install Master Bearings Set D81 T-4222-E or
equivalent to differential case.
2. Remove all nicks, burrs, dirt, etc., from
differential case bearing hubs and rear axle
differential carrier (4141) to allow bearings to
rotate freely.
3. Install outboard differential spacers into rear axle
differential carrier. Assemble differential case
into carrier (less pinion).
4. NOTE: Dial indicator should have a minimum
travel capability of 5.08mm (0.200 inch).
Mount Dial Indicator / Magnetic Base
D78P-4201-B or equivalent as shown. Locate tip
of indicator on flat surface of one of the ring gear
screw spot faces.
5. NOTE: Repeat the following steps until you have
obtained the same reading. Record the reading of
the indicator. This will be the total amount of
differential bearing shims (4067) required (less E9725-A
preload) and will be calculated later during
assembly. 6. Force the differential as far as it will go in the
Force differential (4026) as far as possible in the opposite direction.
direction toward the indicator. With force still 7. After making sure the readings are correct,
applied, set indicator at zero (0). remove indicator and differential from rear axle
housing (4010). DO NOT REMOVE MASTER
BEARING BORE
IN HOUSING
BEARINGS FROM DIFFERENTIAL CASE AT
THIS TIME.
This reading is the Total Differential Case End
Play which will be needed for Assembly of
Differential into Housing in this section.
LEFT-HAND CARRIER
SPACER HOUSING E7657·1A
E7652·C

ALL RIGHTS RESERVED
05-020-16 Axle, Rear, Dana 05-020-16
Pinion Ring Gear Variation Number

NOTE: If baffle or oil slinger is bent or mutilated, it
should be replaced.
Ring gears and pinions are supplied in matched sets
only. Matching numbers on both the pinion and ring
gear are etched for verification. If a new ring gear and
pinion is being used, verify the numbers of each pinion
and ring gear before proceeding with assembly. The
end of the pinion with the etched figures shown is
known as the "button" end.
Use the gear contact pattern method to make sure the
final pinion position is valid. 3
BUTTON END DRIVE

PINION
(PART OF 4209)
E8556-D
On the button end of each pinion, there is etched a plus

(+) number, a minus (-) number, or a zero (0) number
which indicates the best running position for each
particular ring gear. This dimension is controlled by the
shimming behind the inner pinion bearing cup (the
backface).
The distance from the centerline of the ring gear to the
backface of the pinion is 147.6mm (5.812 inches).
E9726-A
Part
1 - Tooth Combination Stamped
Here
2 4663 Pinion Preload Shims
3 4663 Pinion Position Shims
4 - Button End (Part of 4209)
5 - Centerline of Differential
Ring Gear and Pinion
6' 4670 Rear Axle Drive Pinion Shaft
Oil Slinger
7 - Pinion Oil Baffle
A - 148mm
1995 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain July 199·

ALL RIGHTS RESERVED
05-020-17 Axle, Rear, Dana 05-020-17
For example, if a pinion is etched m+8 (+3), this To change the pinion adjustment, pinion shims are
pinion would require .08mm (.003 inch) less drive available in thicknesses of .08, .13 and .25mm (.003,
pinion shims than a pinion etched "0". This means by .005 and .010 inch).
removing drive pinion shims, the mounting distance of 1. Measure each shim separately with a micrometer
the pinion is increased, which is just what an m+8 and add together to get the total shim pack
(+3) indicates. Or if a pinion is etched m-8 (-3), we thickness from the original build up.
would want to add .08mm (.003 inch) more shims than
would be required if the pinion were etched' '0". By If a new ring gear and pinion is being used, notice
adding .08mm (.003 inch) pinion shims, the mounting the (+ ) or (-) etching on both the old and new
distance of the pinion was decreased, which is just pinion and adjust the thickness of the new shim
what an m-8 (-3) indicated. pack to compensate for the difference of these
two figures.
If the old ring gear and pinion is to be reused, measure
the old pinion shims and build a new pack of pinion For example, if the old pinion reads m+5 (+ 2)
shims to this same dimension. If a baffle is used in the and the new is m-5 (-2), add .10mm (.004 inch)
rear axle assembly (4006), it is considered part of the pinion shims to the original shim pack.
shim pack.
New Pinion Marking (English)

Old Pinion
Marking -4 -3 -2 -1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003
0 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004
-1 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005
-2 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006
-3 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007
-4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008
TE4091A
New Pinion Marking (Metric)

Old Pinion
Marking -10 -8 -5 -3 0 +3 +5 +8 +10
+10 +.20 +.18 +.15 +.13 +.10 +.08 +.05 +.03 0
+8 +.18 +.15 +.13 +.10 +.08 +.05 +.03 0 -.03
+5 +.15 +.13 +.10 +.08 +.05 +.03 0 -.03 -.05
+3 +.13 +.10 +.08 +.05 +.03 0 -.03 -.05 -.08
0 +.10 +.08 +.05 +.03 0 -.03 -.05 -.08 -.10
-3 +.08 +.05 +.03 0 -.03 -.05 -.08 -.10 -.13
-5 +.05 +.03 0 -.03 -.05 -.08 -.10 -.13 -.15
-8 +.03 0 -.03 -.05 -.08 -.10 -.13 -.15 -.18
-10 0 -.03 -.05 -.08 -.10 -.13 -.15 -.18 -.20
TE4092A
Pinion Bearing Cup Installation 2. Place the inner bearing cup replacer tool on the
inner differential bearing cup. Use Pinion Bearing
SPECIAL SERVICE TOOL(S) REQUIRED Cup Replacer D81 T-4616-A or equivalent.
Description Tool Number 3. Place the outer bearing cup replacer tool on the
outer differential bearing cup. Use Pinion Bearing
Pinion Bearing Cup Replacer T67P-4616-A Cup Replacer T67P-4616-A.
Threaded Drawbar T75T-1176-A
1. Place the inner and outer differential bearing cups

into the carrier bore.

ALL RIGHTS RESERVED
05-020-18 Axle, Rear, Dana 05-020-18
4. Install the Threaded Drawbar T75T-1176-A into 3. Place the outer drive pinion bearing cone (new or
the replacer tools and tighten the drawbar to used if in good condition) into the pinion bearing
install the differential drive pinion bearing cups cup and assemble the handle onto the screw and
(4616) into the carrier bore. hand tighten.
INSTALLATION OF PINION
DEPTH TOOLS
E7653·B
Part
E1706-K 1 T88T-4020-B Handle
Part 3 T80T-4020-F43 Screw
Item Number Description 4 4621 Differential Pinion Bearing
5 T88T-4020-A Gauge Disc
Bearing Cup (Inner) 6 T80T-4020-F42 Gauge Block
7 D81T-4020-F51 Gauge Tube
2 T67P-4616-A Pinion Bearing Cup Replacer
8 D80T-4020-R60 Aligning Adapter
3 T75T-1176-A Threaded Draw Bar
9 4010 Rear Axle Housing
Bearing Cup (Outer)
4. Center the proper gauge tube into the differential
5 D81T-4616-A Pinion Bearing Cup Replacer bearing bore. Install the bearing caps and tighten
A - Outer Cup Installation View to 94.9-122 N·m (70-90 Ib-ft).
B - Inner Cup Installation View
5. Make sure the shims or feeler gauges are free of
Pinion Position Shim Selection dirt to prevent an incorrect reading.
1. NOTE: If any of the gauge surfaces become 6. NOTE: The feeler gauge fit between the gauge
nicked, the high spots must be removed with a tube and the gauge block should have a slight
medium India oilstone to make sure there are no drag-type feeling.
erroneous readings. Using a feeler gauge tool or shims, select the
Place a new inner drive pinion bearing cone over thickest feeler shim that will enter between the
the proper aligning adapter and insert into the gauge tube and the gauge block. Insert the feeler
axle carrier bore. gauge directly along the gauge block so a correct
reading can be made.
2. The 3/ a-inch square drive in the handle to be
used for obtaining the proper pinion bearing
preload and tighten to preload of 2.26-4.53 N·m
(20-40Ib-in).

ALL RIGHTS RESERVED
05-020-19 Axle, Rear, Dana 05-020-19
7. NOTE: If the service pinion gear is marked with a

plus (+) reading, this amount must be subtracted
from the thickness dimension obtained between
gauge block and gauge tube.
NOTE: If the service pinion gear is marked with a
minus (-) reading, this amount must be added to
the thickness dimension obtained between gauge
block and gauge tube.
NOTE: In addition you must use the exact same
new inner pinion bearing used in the previous
steps.
After the correct feeler gauge feel is obtained, BEARING
check the reading. This is the thickness of pinion
shims required providing that, upon inspection of
the service pinion gear, there are no markings.
8. CAUTION: The drive pinion preload spacer SUITABLE
and pinion shim assembly sequence must be PLATE
followed. If sequence is not followed and
components are improperly assembled, it
may cause unit failure. If pinion shims are
damaged, replace with new ones. Shims are E9727-A
available in the following thicknesses.
10. After following these procedures, continue to
PINION SHIMS build the remaining components with proper
pinion and differential bearing preload torques
mm Inches and differential ring gear and pinion backlash.
.36 .014 11. Assemble pinion shims onto pinion and install
.38 .015 pinion gear into rear axle housing. Assemble
outer bearing cone and roller assembly onto
.41 .016
pinion.
.46 .018
12. Assemble companion (universal joint) flange,
.51 .020 washer and new pinion nut on the pinion shaft.
.53 .021 Tighten nut to 597-677 N·m (440-500 Ib-ft).
.56 .022 13. Using an inch-pound torque wrench, rotate pinion.
.58 .023 Torque to rotate pinion should read 2.26-4.53
N·m (20-40 Ib-in). To increase preload, remove
.76 .030
pinion shims from the outer shim pack. To
9. NOTE: If a baffle or slinger is used, replace with a decrease preload, add shims.
new one upon assembly and measure as part of
the shim stack.
Remove the inner pinion bearing cup and install
the correct thickness of pinion shims in the carrier
bore. Re-install the pinion bearing cup and baffle
(if used). Install oil slinger if an oil slinger is used,
between the pinion gear head and inner pinion
bearing cone. Assemble onto the pinion shaft and
press on the cone with Axle Bearing / Seal Plate
T75L-1165-B and a suitable plate which contacts
the bearing cone.

ALL RIGHTS RESERVED
05-020-20 Axle, Rear, Dana 05-020-20
The direction pointing toward the companion

flange indicates that by removing shims, the Part
distance from the centerline of the tubes to pinion Item Number Description
backface is increased, giving a plus (+) reading. 3 4663 Inner Pinion Bearing
The differential pinion bearing preload shim pack Adjustment Shims (Position)
does not ~ffect the pinion depth setting. However, 4 4067 Differential Bearing Shims
if pinion position is changed, the pinion preload 5 4630 Inner Pinion Bearing
will change and may require adjustment to bring
torque-to-rotation within specification. ArrQws on 14. With the drive pinion at the correct preload as
the ring gear illustrate the method to increase or determined earlier in this procedure, remove the
decrease backlash and differential bearing pinion nut, drive pinion nut locking washer with
preload. Companion Flange Holding Tool T57T-4851-B
If pinion bearing preload is within specification and and Companion Flange Remover T65L-4851-B.
the pinion position is changed, the drive pinion 15. Coat the pinion seal with grease. Install the pinion
bearing adjustment shims (4663) shou'd be seal with Pinion Oil Seal Replacer T88T-4676-A.
changed by the same amount. . After installation, make sure the garter spring did
not pop out. If the garter spring pops out, remove
and replace pinion seal. .
E9728-A
16. Install the companion flange using Companion

Flange Replacer T88T-4851-A.
4 E1729-H
Part
1 4621 Outer Pinion Bearing
2 4663 Outer Pinion Bearing
Adjustment Shims (Preload)
(Continued)
1995 F-150, F-250, F-350, Bronco, F-Super Duty Pqwertrain, Drivetrain July 199<4

ALL RIGHTS RESERVED
05-020-21 Axle, Rear, Dana 05-020-21
17. NOTE: Whenever the companion flange is

removed, the pinion washer and pinion nut should
be replaced.
Install the washer and nut and tighten nut to
597-677 N·m (440-500 Ib-ft).
COMPANION FLANGE
REPLACER
T88T-4851-A
E&409·1B
4. NOTE: Mating letters are stamped on rear axle

bearing retaining caps and carrier. Matching
letters is important at time of assembly. Letters
are in vertical and horizontal positions.
Install differential bearing retaining caps. Align the
letters stamped on the differential bearing
retaining caps with those on the carriers. Tighten
screws of rear axle bearing retaining caps to
95-122 N·m (70-90 Ib-ft).
BEARING CAPS
E9729-A
Assembly of Differential into Housing

Ring Gear and Pinion Backlash
Before installing differential to housing, refer to Ring
Gear and Pinion Backlash Adjustments in this section.
1. NOTE: Care should be taken to avoid nicking the
teeth of the ring gear and speed sensor ring
during assembly.
Assemble differential bearing cups to differential
bearings (4221). Install differential into carrier.
2. Use a rawhide hammer to seat differential into
crossbore of carrier. MAT'NG
3. Remove the spreader from the carrier. LETTERS E8552-B
5. Check ring gear and pinion backlash at three

equally spaced points with dial indicator.
Backlash tolerance is O. 13-0.203mm
(0.005-0.008 inch) and cannot vary more than
0.05mm (0.002 inch) between points checked.
High backlash is corrected by moving the ring
gear closer to the pinion.
Low backlash is corrected by moving ring gear
away from the pinion.

ALL RIGHTS RESERVED
05-020-22 Axle, Rear, Dana 05-020-22
These corrections are made by switching 9. CAUTION: Clean both flat surfaces with a
differential bearing shims (4067) from one side of suitable solvent to remove all traces of oil
the differential case (4204) to the other. film_
Install new axle housing cover gasket and install
axle housing cover (4033). Tighten screws to
41-54 N-m (30-40 Ib-ft) as detailed below.
10. The following figure shows the flat mounting
surface axle housing cover on Dana design rear
axles (4001). This axle housing cover requires
the use of a silicone rubber sealer material such
as Silicone Rubber E7TZ-19562-A or equivalent
meeting Ford specification ESL-M4G273-A
rather than a gasket.
The axle housing cover face of the carrier and the
flat surface of the axle housing cover must be free
of any oil film or foreign material.
Sealant material must meet specifications of
ESL-M4G273-A, ASTM1, GE503, Z1, Z2 and Z3
sealant or equivalent. .
E8555-e
6. To confirm total preload, recheck torque to rotate

with an pound-inch wrench as shown. The reading
should be higher than the initial reading (taken
without the differential case installed as
described under Pinion Position Shim Selection)
by the following amount if new bearings have
been installed as recommended:
4.63 and 5.13 ratios = 6-Blb-in
7. If total preload is too high, remove an equal
amount of differential bearing shims from each
differential case hub. If total preload is too low,
add an equal amount of differential bearing shims
to each differential case hub.
11. NOTE: Axle housing cover must be installed

within 15 minutes of application of the silicone or
new sealant must be applied.
Apply Silicone Rubber E7TZ-19562-A or
ESL-M46273-A to surface of axle housing cover.
Lay sealer bead 3. 1B-6.35mm (1 / B to 1/4 inch)
wide on the inside of the axle housing cover
screw holes. The bead is not to pass through the
holes or outside of the holes.
12. Assemble two axle housing cover screws into
axle housing cover at Bo'clock and 2 o'clock
position. Use these two holes to guide axle
housing cover into position on the carrier.
B. To verify the final pinion position, refer to 13. Install remaining screws. lighten alternately and
Adjustments, Ring Gear and Pinion Tooth Pattern evenly. lighten screws to 41-54 N-m
Interpretation in this section. (30-40 Ib-ft). Allow one hour cure time before
filling carrier with the proper amount of specified
lubricant. Refer to the Specifications portion of
this section.
14. Install axle shaft (4234). Refer to Section 05-02E.

ALL RIGHTS RESERVED
05-020-23 Axle, Rear, Dana 05-020-23
15. Fill rear axle housing (4010) with specified

amount of rear axle lubricant meeting Ford
specification WSP-M2C 197-A. Refer to
Specifications, Lubricant Capacities in this
section.
Inspection Before Disassembly

1. Inspect differential case (4204) and drive pinion
prior to removal from the rear axle assembly
(4006). These inspections can find the cause of
the concern and determine the resolution.
2. Wipe the lubricant from the internal working parts
and visually inspect the parts for wear and / or E8555-e
damage.
3. Rotate the gears to check for any roughness,
indicating damaged bearings or gears.
4. Check the teeth of ring gear and pinion for signs Inspection After Disassembly
of scoring, abnormal wear or nicks / chips.
1. CAUTION: The bearing assemblies will fail if
5. Set up Dial Indicator / Magnetic Base Tool they do not seat firmly against the shoulders.
D78P-4201-B or equivalent and check backlash
and backface runout of ring gear and pinion. Thoroughly clean all parts. Always use new
solvent when cleaning bearings. Do not spin dry
6. Check ring gear and pinion backlash at three bearings with compressed air.
2. Oil the bearings immediately to prevent rusting.
Backlash tolerance is 0.127-0.203mm
(0.005-0.008 inch) and cannot vary more than 3. Inspect the parts for any major damage.
0.05mm (0.002 inch) between points checked. 4. Clean the inside of the differential case (4204)
before rebuilding.
• High backlash is corrected by moving the ring
gear toward the pinion. 5. When a scored or chipped ring gear and pinion is
replaced, the axle housing must be washed
• Low backlash is corrected by moving the ring thoroughly.
gear away from the pinion.
Inspection procedures for individual parts follow.
• These corrections are made by switching
differential bearing shims (4067) from one side Bearing Cups
of the differential case to the other. Check bearing cups for deep scores, galling, or
7. To check backface runout of ring gear and pinion, spalling.lf a 0.0381mm (0.00 15-inch) feeler gauge
mount Dial Indicator / Magnetic Base can be inserted between a pinion bearing cup and the
D78P-4201-B or equivalent on the carrier so the bottom of its bore at any point around the pinion
tip of the dial indicator contacts the backface of bearing cup, the pinion bearing cup must be re-seated.
the ring gear and pinion. Backface runout should
be no more than 0.101mm (0.004 inch). If more
Cone and Roller Assemblies
than 0.002 inch difference in backlash is When operated in the bearing cups, bearing rollers
measured at adjacent points, the total runout will must turn without roughness. Examine the roller ends
be beyond specifications. for step wear. If inspection reveals either a damaged
cup or a damaged cone and roller, both parts should
be replaced.
Companion (Universal Joint) Flange
Be sure that the flange lugs have not been damaged in
removing the driveshaft (4602) or in removing the
pinion seal from the pinion. The end of the flange that
contacts the bearing cone as well as the nut
counterbore and surface of pinion seal must be smooth
and free of nicks.

ALL RIGHTS RESERVED
05-020-24 Axle, Rear, Dana 05-020-24
Gears 2. Set up dial indicator as shown. Locate dial

Examine the teeth of ring gear and pinion for scoring, indicator on a flat surface of one of the ring gear
excessive wear, nicks and excessive chipping. Worn, and pinion screws.
scored and damaged ring gear and pinion cannot be 3. Force the differential case assembly (ring gear)
rebuilt to correct a noisy condition. away from the pinion gear. With force still applied
to the differential case set indicator at zero.
Speed Sensor Ring
Examine teeth of speed sensor ring. Replace if any are
broken or missing.
Carrier Housing
Make sure that the differential and differential pinion
bearing bores are smooth. Remove any nicks or burrs
from the mounting surfaces of the carrier housing.
Differential Case
Make sure that the hubs where the bearings mount are
smooth. Carefully examine the bearing shoulders of
differential case, which may have been damaged
when the bearings were removed.
Check the fit (free rotation) of the differential side
gears (4236) in their counterbores.
ADJUSTMENTS
Refer to Section 05-02E for adjustment of rear wheel

bearings procedures and specific adjustments of rear
hubs (1109).
Refer to Section 06-04 for rear disc brake assembly
and disassembly procedures.
,/
,/ E8557-B
Ring Gear and Pinion Backlash 4. NOTE: Repeat the following step until the same
reading is obtained each time. This reading will be
1. Place differential (4026) into axle housing. the necessary amount of pinion shims required
Differential master bearings should still be between the differential case and differential
assembled to differential case (4204). Install bearings (4221) on the ring gear and pinion side.
outboard spacers in same side as removed from,
when making overall measurement. Force the differential case assembly (ring gear)
into mesh with the pinion gear to obtain an
BEARING BORE indicator reading.
IN HOUSING
5. Remove indicator and differential case from the
carrier.
6. Remove master bearings from differential case.
LEFT-HAND CARRIER
SPACER
E7657·1A
HOUSING
1995 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain July 199.1

ALL RIGHTS RESERVED
05-020-25 Axle, Rear, Dana 05-020-25
7. As determined in the measurement obtained

under Differential Case End Play Check earlier in
this section, place the required amount of shims
on the ring gear hub of the differential case. For
example, if the reading was 1. 14mm (0.045
inch), place 1. 14mm (0.045 inch) of shim on the DIFFERENTIAL
hub of the ring gear side of the differential case. BEARING CONE
REPLACER
D81 T-4221-A
E9730-A
13. CAUTION: Do not spread rear axle

E7652-C differential carrier (4141) over 0.38mm
(O.015inch).
8. Install the bearing cone on the ring gear side of
Install Differential Housing Spreader
the differential case. Drive the bearing onto the
TOOL-4000-E and Dial Indicator I Magnetic Base
hub using Differential Bearing Cone Replacer
D78P-4201-B or equivalents to carrier. Do not
D81 T-4221-A or equivalent.
spread carrier over 0.38mm (0.015 inch).
9. To determine the correct amount of shims to be Remove indicator.
placed on the hub of the drive pinion side of the
differential case, subtract the reading obtained in
this procedure from the Total Differential Case DIAL INDICATOR/ DIFFERENTIAL
MAGNETIC BASE HOUSING SPREADER
End Play. Total Case End Play was determined D78P-4201-8 TOOL-4000-E
under Differential Case End Play Check. When
this amount is determined, add 0.25mm (0.010
inch). This is the required amount of shims to be
placed on the hub of the drive pinion side of the
differential case.
For example, Total Differential Case End Play
was 2.30mm (0.091 inch). The reading in Step 3
was 1.14mm (0.045 inch), and when subtracted
from 2.30mm (0.091 inch) gives 1.16mm (0.046
inch). 0.25mm (0.010 inch) is added to give
1.41 mm (0.056 inch) amount of pinion shims to
be placed on the hub of the drive pinion side of the
differential case.
10. Install required amount of pinion shims on the hub
of the drive pinion side of the differential case.
11. Install the bearing cone on the hub of the drive ~---- 292 mm ----~
pinion side of the differential case. Place Step (11.50 INCH)
SPREADER HOLE TO
Plate D80L-630-8 on the ring gear side bearing to SPREADER HOLE E8558-C
protect the bearing during installation of the drive
pinion side bearing.
12. Drive the bearing onto the drive pinion side hub
using Differential Bearing Cone Replacer
D81 T-4221-A or equivalent.

ALL RIGHTS RESERVED
05-020-26 Axle, Rear, Dana 05-020-26
Ring Gear and Pinion Tooth Pattern Ring Gear Pattern Interpretation
Interpretation
Gear Tooth Contact Pattern Check
1. To check the gear tooth contact, paint the gear HEEL TOE TOE HEEL
.~@~
teeth with the special marking compound. A
mixture that is too wet will run and smear; too dry
a mixture cannot be pressed out from between
the teeth.
2. Rotate the ring gear (use a box wrench on the
ring gear attaching bolts as a lever) several
complete revolutions in both directions or until a
clear tooth conta9t pattern is obtained.
3. Certain types of gear tooth contact patterns on
the ring gear indicate incorrect adjustment.
Incorrect adjustment"can b.e corrected by
readjusting the ring gear and / or the pinion.
4. The illustration shows acceptable tooth patterns
for all axles. In general, desirable tooth patterns
should have the following characteristics:
c. Some clearance between the pattern and the
top of the tooth is desirable.
d. There should be no hard lines where the
pressure is high.
E8232-e
Part
A - Normal or Desirable Pattern
(Part of 4209)
B - Backlash Correct. Thinner
Pinion Position Shim
Required (Part of 4209)
C - Backlash Correct. Thicker
Pinion Position Shim
Required
(Part of 4209)
D - Pinion Position Shim Correct.
Decrease Backlash
(Part of 4209)
E - Pinion Position Shim Correct.
Increase Backlash
(Part of 4209)
Pattern Movements Summarized

1. Decreasing backlash moves the ring gear closer
to the pinion.
Drive pattern (convex side of gear) moves
slightly lower and toward the toe.
Coast pattern (concave side of gear) moves
lower and toward the toe.
1995 F-150, F-250, F-350, Bronco, F-Super Duty P9wertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
05-02D-27 Axle, Rear, Dana 05-02D-27
2. Increasing backlash moves the ring gear away • Thinner shim, with the backlash set to
from the pinion. specifications, moves the pinion farther from the
Drive pattern moves slightly higher and toward ring gear.
the heel. • Thicker shim, with the backlash set to specification,
Coast pattern moves higher and toward the moves the pinion closer to the ring gear.
heel. If the pinion positioning shims are correct:
3. Thicker pinion position shim with the backlash • Decreasing backlash moves the ring gear closer to
constant moves the pinion closer to the ring gear. the pinion. Drive pattern (convex side of gear)
Drive pattern moves deeper on the tooth (flank moves slightly lower and toward the toe. Coast
contact) and slightly toward the toe. pattern (concave side of gear) moves lower and
toward the toe.
Coast pattern moves deeper on the tooth and
toward the heel. • Increasing backlash moves the ring gear away from
the pinion. Drive pattern moves slightly higher and
4. Thinner pinion position shim with the backlash
toward the heel. Coast pattern moves higher and
constant moves the pinion further from the ring
toward the heel.
gear.
If the patterns are not correct, make the changes as
Drive pattern moves toward the top of the tooth
indicated. The differential case and drive pinion will
(face contact) and toward the heel.
have to be removed from the carrier housing to
Coast pattern moves toward the top of the tooth change a shim.
and slightly toward the toe.
Check ring gear backlash by installing a dial indicator
An individual gear set need not conform exactly to the on the carrier housing. Check ring gear and pinion
ideal pattern to be acceptable. Any combination of backlash at three equally spaced points on the ring
drive and coast patterns shown is acceptable. gear. Backlash tolerance is 0.23mm (0.005-0.008
Since each gear set rolls a characteristic pattern, the inch) and cannot vary more than 0.05mm (0.002 inch)
patterns shown are considered acceptable and should between the three points. If backlash is high, the ring
be used as a guide. The drive pattern is rolted on the gear must be moved closer to the pinion, by moving
convex side of the tooth, and the coast pattern is shims to the ring gear side to the opposite side. If
rolled on the concave side. backlash is low, the ring gear must be moved away
from the pinion by moving shims from the ring gear'
NOTE: When making pinion position changes, shims side to the opposite side.
should be changed in the range of .05mm (.002 inch)
to .10mm (.004 inch) until correct pattern has been
obtained.
The movement of tooth contact patterns with changes
in shimming can be summarized as follows:
SPECIFICATIONS
LUBRICANT CAPACITIES
Approximate Capacities
Ford Specification U.S. Pts. I Imperial Pts. I Liters
WSP-M2C 197-A 8.5 I 7.0 I 4.0
NOTE: Use additive friction modifier WSP-M2C 196-A or equivalent meeting Ford specification WSP-M2196-A for
complete refill of Dana limited slip rear axles (4001).
AXLE ADJUSTMENTS
Description Specification Description Specification
Backlash Between Differential Ring Gear 0.13-0.20mm Pinion Bearing Preload (with New 2.26-4.53 N·m
and Pinion (0.005-0.008 Inch) Bearings) (20-40 Lb-In)
Backlash Maximum Variation Between 0.05mm Total (Pinion Plus Differential) Add 6-9 Lb-In,
Checkpoints (0.002 Inch) Preload with New Bearings Depending
on Ratio, to Pinion
Preload.
ALL RIGHTS RESERVED
05-02D-28 Axle, Rear, Dana 05-02D-28
SPECIFICATIONS (Continued) SPECIAL SERVICE TOOLS/EQUIPMENT
WARNING: IF FASTENERS OF A LOWER GRADE SPECIAL SERVICE TOOLS REQUIRED

OR CLASS ARE TIGHTENED TO THE Tool Number /
REQUIREMENTS OF A HIGHER GRADE OR CLASS Description Illustration
FASTENER, IT MAY RESULT IN COMPONENT
FAILURE (E.G., GRADE 5 FASTENER TIGHTENED T50T-100-A
~
Impact Slide Hammer - 2-1 /2
TO THE REQUIREMENTS OF A GRADE 8
Lbs. (Oil Seal Removal)
FASTENER). T50T-l00-A
Inch grade fasteners can be identified by the radial T77F-1102-A

lines embossed upon the head of the fastener and will Bearing Cup Replacer (Oil Seal
correspond to the fastener strength by two lines less Removal)
than actual grade (i.e., grade 8 fastener will display 6
radial lines on the head).
Metric fastener strength can be identified with the
class identification embossed on the head of each T77F-ll02·A
fastener. Increasing numbers represent increasing
strength. T75L-1165-B
~17IL-11'"
Axle Bearing / Seal Plate (Drive
Pinion Bearing Installation)
T75L-1165-DA
Axle Bearing / Seal Replacer
~~~
(Drive Pinion Bearing
Installation - Model 60)
cy~~ T75T-1176-A
T75L·1185-DA
GRADE 5 GRADE 7 GRADE 8 GRADE 9 Threaded Drawbar

(HIGH STRENGTH
APPLICATIONS)
CUSTOMARY (INCH) BOLTS T75T-117I-A
T80T-4000-W
Driver Handle (Bearing Cup
GGGO
Removal and Installation)
TIOT~OOO-W
T80T-4020-A
Pinion Depth Gauge (Axle
Adjustments)
METRIC BOLTS
E9237-B
Pinion Shaft Nut 597-677 440-500
Differential Bearing Cap Bolts 95-122 70-90
Ring Gear Attaching Bolts 272-325 200-240
Oil Filler Plug - 1/ 41nch Recess 27-41 20-30
Drive
V-Joint Bolts - -
T80T-4020-A
Cover to Housing Bolts 41-54 30-40
Sensor (ABS) 34-47 25-35 T53T-4621-C
Pinion Bearing Cone Replacer
Brake Caliper Mount Bracket Bolts 100-135 74-100
Axle Shaft to Hub Bolts 114-153 84-113
T53T-4821-e
(Continued)

ALL RIGHTS RESERVED
05-02D-29 Axle, Rear, Dana 05-02D-29

(Continued)

Tool Number / Tool Number Description
D80l-630-1 Step Plate (Wheel Bearing Installation)
T57T-4851-B
D80l-630-8 Step Plate (Differential Side Bearing
.~
Installation)
(Yoke Removal and Installation)
D81l-4000-A Drive Handle (Bearing Cup Removal)
T57T-4851-8
D78P-4201-B Dial Indicator / Magnetic Base (Axle
Adjustments)
T65l-4851-B D81l-4220-A Pinion and Carrier Bearing Puller
~
Companion Flange Remover
(Yoke Removal) D81T-4221-A Differential Bearing Cone Replacer
(Differential Side Bearing Installation)
T85T-4209-AH D81T-4222-E Master Bearings (Axle Adjustments)

Pinion Shaft Thread Protector D81T-4616-A Pinion Bearing Cup Replacer
~ D81T-4628-B
D81T-4628-X
Bearing Cup Remover
Pinion Bearing Cup Remover Set
TaT-4201-AH
D80l-1 002-l 2-Jaw Puller (Pinion Flange Removal)
T67P-4616-A
081 T-4020-F51 Gauge Tube (Axle Adjustment)
~
D81T-4020-F56 Gauge Block (Axle Adjustment)
D81T-4222-E Master Bearing-Ditt. Case (Axle
Adjustment)
T67P-4816-A
TOOl-1175-AC Seal Remover
T88T-4628-A
TOOl-4000-E Differential Housing Spreader
Outer Bearing Cup Remover
@
TIIT-4628-A
T88T-4676-A
t@
Pinion Oil Seal Replacer
cr
TilT-4876-A
T88T-4851-A
Companion Flange Replacer
~
T.T-4851-A

ALL RIGHTS RESERVED
05-02E-1 Wheel Hubs and Bearings, Rear, Dana Full-Floating Axle 05-02E-1
SECTION 05-02E Wheel Hubs and Bearings, Rear,

Dana Full-Floating Axle
VEHICLE APPLICATION ••••..••••.•••••...••••••••..••.••••.••.•••05-02E-1 ADJUSTMENTS
DESCRIPTION AND OPERATION Wheel Hubs and Bearings .••..•..•••••••.••••••••••••••..••••05-02E-5
Wheel Hubs and Bearings ••.••••••.•.•••••.••••••••.•••••••••05-02E-1 SPECIFICATIONS •.••••••••••••••••••••••.••••••••••••••.•••.••••••••05-02E-5
DIAGNOSIS AND TESTING SPECIAL SERVICE TOOLS/EQUIPMENT .•••••••..••••••••05-02E-6
Wheel Hubs and Bearings •••.••••••.••••••••.•••.••••••••••••05-02E-1
Bearings, Cups and Seals •••••••••••••.•••....••.•••...••.•••05-02E-2
VEHICLE APPLICATION
F-Super Duty and F-Super Duty Commercial and
Motorhome Chassis Vehicles
Wheel Hubs and Bearings Dual rear wheels are attached to the rear hub with
integral two-piece swiveling lugnuts.
The F-Super Duty full-floating axle features disc
brakes. The rear disc brake rotor is mounted to the WARNING: ON REAR AXLES WITH DUAL REAR
rear hub (1109). The rear hub is supported or floats on WHEELS, DO NOT ATTEMPT TO USE PRE-1985
the axle spindle on two opposing tapered roller LUGNUTS (CONE-SHAPED, ONE-PIECE) TO
bearings. The rear hub is retained on the spindle by a REPLACE THE INTEGRAL TWO-PIECE
ratcheting nut tabbed to a slot on the spindle. SWIVELING LUG NUTS (1012). OLDER VEHICLE
LUGNUTS CAN COME LOOSE IN VEHICLE
A seal is installed behind the rear wheel bearing inner
OPERATION. DO NOT ATTEMPT TO USE OLDER
cone and roller (1244) to prevent rear axle lubricant
VEHICLE WHEELS, WHICH HAVE CONE-SHAPED
from leaking.
LUGNUT SEATS, ON THIS VEHICLE. DO NOT
The rear wheel bearings are packed with a lithium ATTEMPT TO USE THE NEW DESIGN WHEELS
base grease, Premium Long-Life Grease XG-1-C or -K AND LUG NUTS ON OLDER VEHICLE WHEEL
or equivalent meeting Ford specification HUBS. ATTEMPTED USE OF INTERMIXED
ESA-M1C75-B, to provide initial lubrication until axle WHEELS CAN LEAD TO DAMAGE TO THE WHEEL
lubricant flows into the rear hubs and rear wheel MOUNTING SYSTEM AND COULD RESULT IN
bearing inner cone and rollers during vehicle operation. WHEELS (1007) COMING LOOSE IN OPERATION.
These rear axles (4001) are vented through the rear
axle housing vent (4022) in the left axle tube.
Wheel Hubs and Bearings

ALL RIGHTS RESERVED
NOTE: For disassembly and assembly procedures for

rear hubs (1109) and rear wheel bearings on Ford
full-floating rear axles (4001), refer to Section 05-028.
Bearings, Cups and Seals Disassembly

WARNING: DO NOT ATTEMPT TO USE OLDER 1. Set the parking brake and loosen the axle shaft
VEHICLE LUGNUTS (CONE-SHAPED, ONE-PIECE) attaching bolts.
TO REPLACE THE INTEGRAL TWO-PIECE 2. Raise the rear wheels ( 1007) off the floor and
SWIVELING LUG NUTS (1012). IF SO USED, place safety stands under the rear axle housing
PRE-1985 LUGNUTS CAN COME LOOSE IN (4010).
VEHICLE OPERATION. DO NOT ATTEMPT TO USE
OLDER VEHICLE WHEELS, WHICH HAVE 3. Release the parking brake.
CONE-SHAPED LUGNUT SEATS, ON THIS 4. Using a heavy-duty wheel dolly such as Rotunda
VEHICLE. DO NOT ATTEMPT TO USE THE NEW Wheel Dolly 014-00030 or equivalent, raise the
DESIGN WHEELS AND LUG NUTS ON PAST wheel to the point that all weight is removed from
MODEL WHEEL HUBS. ATTEMPTED USE OF the wheel bearings. Remove the wheel.
INTERMIXED WHEELS CAN LEAD TO DAMAGE TO
THE WHEEL MOUNTING SYSTEM AND COULD 5. Place a drain pan under the rear hub (1109).
RESULT IN WHEELS COMING LOOSE IN Remove the axle shaft attaching bolts and
OPERATION. discard them.
6. Remove the axle shaft (4234) and discard the
SPECIAL ~ERVICE TOOL(S) REQUIRED rear wheel gasket (1001).
Description Tool Number 7. Remove the caliper as described in Section
06-04.
Outer Bearing Cup Remover T88T-1175-A
Inner Bearing Cup Remover T88T-1175-B
Bearing Cup Replacer T88T-1175-C
Hub Seal Replacer T91T-1175-AH
Hub Locknut Wrench T88T-4252-A
Bearings, Cups and Seals
F5648-E
ALL RIGHTS RESERVED
Part Part
1 1012 Lug Nut 10 1175 Inner Hub Seal
2 1007 Wheel 11 1244 Rear Wheel Bearing Inner
3 1109 Rear Hub and Rotor Cone and Roller
Assembly 12 1240 Rear Wheel Bearing Outer
4 2B120 Disc Brake Caliper Cone and Roller
5 4001 Dana Full-Floating 13 1A 124 . Hub Nut
Axle-Model 80 14 4234 Axle Shaft
6 4A140 Axle Shaft-to-Rear Hub Bolt A - Tighten to 190 N·m
7 1001 Rear Wheel Gasket (140 Lb-Ft)
8 1239 Outer Bearing Cup B - Tighten to 113-153 N·m
(83-113 Lb-Ft)
9 1243 Inner Bearing Cup
C - Refer to Specifications.
(Continued)
8. Remove the wheel bearing hub nut using Hub

Locknut Wrench T88T-4252-A, so that the drive Part
tangs engage the four slots of the hub nut. Item Number Description
3 - Slot (Part of 1A 124)
4 - Drive Tang
(Part of T88T-4252-A)
5 T88T-4252-A Hub Locknut Wrench
6 1A124 Hub Nut
(65-75 Lb-Ft) while rotating
hub. After tightening, ratchet
back 90 0 , then tighten to
20-27 N·m (15-20 Lb-Ft). The
maximum torque to rotate
the hub is 2-3 N·m (20 Lb-Ft).
Wheel end play is O.OOmm
(.000 In.).
9. Remove the outer bearing cone and pull the rear

hub and rotor assembly straight out and away
from the rear axle (4001).
10. Thoroughly clean the spindle of the rear axle
housing.
11. Carefully remove the inner seal from the rear hub
assembly with a screwdriver, avoiding damage to
the bearing or hub bore.
12. Discard the seal and remove inner wheel bearing
cone and roller.
13. Clean all old grease and axle lubricant out of the
rear hub.
E767G-O
Part
1 - Valve Stem Alignment Pin
(Dual Rear Wheel Only)
(Part of 1109)
2 - Wheel Pin Locating Hole
(Part of 1109)
(Continued)

ALL RIGHTS RESERVED
14. Inspect the bearing races and rollers for pitting, Bearing Cup and Seal Installation - Drum Brakes
galling or erratic wear patterns. Inspect the Shown - Disc Brake Procedure Similar
rollers for end wear.
SINGLE AND DUAL

REAR WHEEL
15. NOTE: The hub can be removed from the rotor by
removing the ten bolts. Refer to Section 06-04.
Replace the rear hub if any of the following
conditions exist:
• cracked material around bolt holes
• depth of holes (40mm [ 1.57 inches])
• threaded for 25mm (1 inch) INSTALLING BEARING CUP
• oversized holes
16. Remove the inner bearing cup with Inner Bearing
Cup Remover T88T-1175-B.
17. Remove the outer bearing cup with Outer Bearing
Cup Remover T88T-1175-A.
18. Inspect the bearing races and rollers for pitting,
galling or excessive wear. If either component
(cup or cone and roller) of the tapered roller INSTALLING SEAL E9812-A
bearing is not usable, replace both components.
19. Install the new cups with Bearing Cup Replacer Part
T88T-1175-C and Threaded Drawbar Item Number Description
T75T-1176-A.
1 1175 Inner Hub Seal
2 1244 Rear Wheel Bearing Inner
Cone and Roller
3 1240 Rear Wheel Bearing Outer
Cone and Roller
4 4234 Axle Shaft
5 T88T-1175-C Bearing Cup Replacer
6 T75T-1176-A Threaded Drawbar
7 - Forcing Nut
(Part of T75T-1176-A)
8 T91T-1175-AH Hub Seal Replacer
Assembly
1. Check for proper seating of the new bearing cups
by trying to insert a 0.038mm (0.0015-inch)
feeler gauge between the cups and the rear hub.
The gauge should not enter beneath the cup.
Check in several places to be sure the cups are
squarely seated.

ALL RIGHTS RESERVED
2. Pack each bearing cone and roller assembly with 10. Prior to installation of the axle shaft, clean and
Premium Long-Life Grease XG-1-C or -K or remove any debris in the hub bolt holes.
equivalent meeting Ford specification 11. Inspect axle shaft for:
ESA-M1C75-B. Use a bearing packing tool such
as Rotunda Bearing Packer 108-R 1141 or • cracked material around the holes
equivalent.
• oversized holes
3. Place the rear wheel bearing inner cone and roller
Replace axle shaft if any of these conditions
(1244) in the hub.
exist.
4. Install a new inner hub seal with Hub Seal
12. Install the axle shaft and rear wheel gasket.
Replacer T91T-1175-AH and Threaded Drawbar
T75T-1176-A. 13. Using new bolts, coat the bolt threads with a
suitable thread adhesive and install the bolts until
5. Wrap the threads of the spindle with electrician's
they seat.
tape to prevent damage while installing rear hub.
14. Install the wheels.
6. Position the rear hub at the rear axle housing.
15. Remove safety stands and lower the vehicle to
7. Carefully slide the rear hub over the axle housing
the floor.
spindle. Remove the electrician's tape.
16. Tighten the lug nuts to specifications.
8. Install the outer wheel bearing cone and roller and
start the bearing hub nut making sure the hub tab 17. Tighten the axle shaft rear hub retaining bolts to
is properly located in the keyway prior to thread 113-153 N·m (83-113 Ib-ft).
engagement.
ADJUSTMENTS
KEYWAY
Wheel Hubs and Bearings

For rear wheel bearing adjustments, refer to Bearings,
Cups and Seals under Disassembly and Assembly in
this section.
For adjustment procedures for rear hubs (1109) and
bearings on Ford full-floating rear axles (4001), refer
to Section 05-02B.
SPECIFICATIONS
E9811-A
Dual Rear Wheel Vehicles with 190 140
9. NOTE: This procedure is intended to provide no
Integral Two-Piece Swiveling
side-to-side end play of the hub and rotor Lugnuts (1 O-Lug Wheel -
assembly. This may be verified with a dial 9/16-18)
indicator magnetically mounted to the spindle end
Hub Nut 88-102 65-75
with the indicator on the outboard surface of the
hub. (To set bearings, back off the hub 20-27 15-20
nut 90 degrees, retighten.)
Install the Hub Locknut Wrench T88T-4252-A so Axle Shaft Retaining Bolts 113-153 83-113
that the drive tangs of the tool engage the four
slots of the nut. Apply inward pressure to the NOTE: Torque specifications are for clean,
socket to separate the ratcheting components of dirt-and-paint-free, dry bolt and nut threads. Never use
the nut, tighten to 88-102 N·m (65-75Ib-ft). Back oil or grease on studs or nuts.
off 90 degrees, then retighten to 20-27 N·m
(15-20 Ib-ft). Rotate hub occasionally while
tightening to set the bearings.
1995 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain July 199~

ALL RIGHTS RESERVED

Tool Number / Tool Number /
Description Illustration Description Illustration
T75T-1175-A or B T88T-1175-A
~'1175-A
Seal Replacer Outer Bearing Cup Remover
T88T-1175-B
~17I~
Inner Bearing Cup Remover
T88T-1175-C
~
T75T·1175-A
T75T-1176-A
Threaded Drawbar TIIT-117S-c
T91T-1175-AH
~
Rear Hub Seal Replacer
T7IT·1171-A
TI1T·1175-AH
T75T-1225-A or B
SPECIAL SERVICE TOOLS DESIRED
D78T-1197-A Front Wheel Bearing Spanner
T7IT·1225-A ROTUNDA EQUIPMENT

T85T-4252-AH
Model Description
Locknut Wrench
014-00030 Wheel Dolly
108-R1141 Bearing Packer
TUT-4212-AH
(Continued)

ALL RIGHTS RESERVED
05-02F-1 Differential, Dana Limited Slip 05-02F-1
SECTION 05-02F Differential, Dana Limited Slip

VEHICLE APPLICATION ••..•••....••.•...•••..•••...•.•.••.•..••..OS-02F·1 DISASSEMBLY AND ASSEMBLY
DESCRIPTION AND OPERATION Axle, Dana Limited Slip .•••.....••..•...•••••.•••••••..•.•.••••OS-Q2F-2
Differential~ Dana Limited Slip.•••••.••..•••.•••.•.••••••.••OS-Q2F·1 Differential Case •.•••...•••.•..•••••..•••...•..••..••••.••...•..•OS-02F·3
DIAGNOSIS AND TESTING SPECIFICATIONS •..•••.•••..•••••...•••.•.••••.••••••••.•• ~ •••..•••.05-02F·e
Different~al, Dana Limited Slip••••..••.•.•.•••.•••••...•...•OS·02F-2 SPECIAL SE~VICE TOOLS/EQUIPMENT ....•...•...•.•.••OS·02F-E
Differential, Dana Limited Slip••..••••.••••...•..•••.....••.OS-02F-2
VEHICLE APPLICATION
F-150 4x4 and Bronco Front Axle Vehicles
DESCRiPtiON AND OPERATION
Differential, Dana Limited Slip The limited slip differential (4026) is similar to a
The limited slip Dana Trac-Lok@ Model441FS has a conventional differential, except part of the torque
from the ring gear is transmitted through differential
power flow identical to a conventional rear axle
clutch packs between the differential side gears
(4001), plus a more direct power flow which
(4236) and differential case. The differential clutch
automatically takes effect as driving conditions
paqks are engaged by a preload from dished springs
demand. This more direct power flow is from the
and separating forces from the differential side gears.
differential case (4;204) to each axle shaft (4234)
This occurs as torque is applied through the ring gear.
through differential clutch packs.
Two-Pinion Limited Slip Differential, Model 44 IFS Trac-Lok@
Part Part
Item Number Description Item Number Des~ription
1 4204 Differential Case 4 - Retainer Clip (Part of 4880)

2 4241 Differential Pinion Shaft Lock 5 4230 Differential Pinion Thrust
Pin Washer
3 4236 Differential Side Gear 6 4215 Differential Pinion Gears

ALL RIGHTS RESERVED
OS-02F-2 Differential, Dana Limited Slip OS-02F-2
Part Part
7 - Dished Spacer (Part of Rear 8 - Clutch Disc (Part of 4880)
Axle Disc and Plate Kit) May 9 - Clutch Plate (Part of 4880)
Have External Lugs, Like the 10 4211 Differential Pinion Shaft
Plate
(Continued)
Limited Slip Differential Power Flow with Both The limited slip differential has the same power flow as
Wheels Driving a conventional differential plus a more direct flow
which automatically takes effect as driving conditions
demand. This more direct flow is from the differential
case to each axle shaft through a clutch plate and disc
arrangement. Arrangement of these plates and discs
is at the option of the vehicle manufacturer, so care
should be taken during disassembly to note the
arrangement of these components.
In diagnosis of vehicle operators' complaints, two
things should be recognized:
• If, with unequal traction, both wheels slip, the limited
slip has done all it can possibly do.
• In extreme cases of differences in traction, the
wheel with the least traction may spin after the
limited slip has transferred as much torque as
possible to the non-slipping wheel.
Each differential clutch pack is premeasured for
proper stack height. Do not separate differential
clutch packs and inter-mix the clutch plates and clutch
discs from the differential clutch packs.
Differential, Dana Limited Slip

Differential, Dana Limited Slip

E9717-A
The Dana limited slip differential (4026) is removed
and installed in exactly the same manner as the
Part conventional differential. For these service procedures
Item Number Description refer to Section 05-02A.
1 - Drive Pinion (Part of 4209)
2 4215 Differential Pinion Gear
3 4880 Differential Clutch Pack DISASSEMBLY AND ASSEMBLY
4 4236 Differential Side Gear
5 4204 Differential Case Axle, Dana Limited Slip
6 - Differential Ring Gear When axle lubricant has been drained for front axle
(Part of 4209) repair (limited slip only), refill the axle with the
A conventional differential transmits all of the ring rear specified quantity of 4x4 Gear Oil F 1TZ-19580-A
torque through the differential side gears to the axle (WSL-M2C191-A) and add .089L (3 ounces) of
shafts. Torque is at all times equal on the axle shafts Additive Friction Modifier C8AZ-19B546-A or
and if one wheel slips, the other wheel can only put out equivalent friction modifier meeting Ford specification
as much torque as the slipping wheel. EST-M2C 118-A.

ALL RIGHTS RESERVED
05-02F-3 Differential, Dana Limited Slip 05-02F·3
NOTE: 4x4 Gear Oil F1TZ-19580-A 4. Remove the differential pinion shaft with a
(WSL-M2C191-A) is used in alilFS model axles. hammer and drift.
F 1TZ-19580-A (WSL-M2C 191-A) has no equivalent.
DO NOT USE ANYTHING ELSE.
DIFFERENTIAL
PINION SHAFT
4211
Differential Case
Driver Handle T83T-4205-A 1
Forcing Nut T83T-4205-A2
Forcing Screw T83T-4205-A3
Step Plate T83T-4205-A4
Disassembly
1. It is not necessary to remove the differential
E2430·F
bearings to overhaul the limited slip differential
(4026); however, the ring gear will have to be
5. Position the Step Plate T83T-4205-A4 into the
removed first.
bottom differential side gear. Apply grease to the
To remove and install the differential side gears centering hole of the step plate.
(4236), differential pinion gears (4215),
differential pinion thrust washers (4230) and
differential clutch packs during disassembly and
assembly requires special procedures and
tooling.
2. NOTE: An axle shaft (4234) placed in a vise, with
the splines extending above the jaws of the vise
not more than three inches, makes an excellent
holding fixture after the differential case (4204)
has been removed from the left axle support arm.
Place a few shop towels over the vise to prevent
the ring gear teeth from being nicked. Remove
the ring gear bolts. Tap the ring gear with a
rawhide hammer to free it from the differential
case. Remove the ring gear from the vise.
3. Use small drift to remove the differential pinion
shaft lock pin (424 ~) retaining the differential
pinion shaft (4211).
~u~
-=== ~ E6666-C
E7153-1A
ALL RIGHTS RESERVED
6. Install Forcing Nut T83T-4205-A2 and Forcing

Screw T83T-4205-A3 into the differential case.
DIFFERENTIAL
PINION THRUST
FORCING SCREW WASHERS
T83T-4205-A3 4230
FORCING NUT
T83T-4205-A2 STEP PLATE
T83T-4205-A4
E5850-C
I
7. Guide the forcing screw onto the step plate. E7370-B
10. NOTE: The following step is very important to

relieve the pressure of the differential clutch
pack.
FORCING SCREW Momentarily, loosen the forcing screw.
T83T-4205-A3
11. NOTE: When attempting to rotate the differential
side gear, some tightening or loosening of the
forcing screw will probably be required to permit
gear movement.
Retighten the forcing screw until a very slight
FORCING NUT
T83T-4205-A2 movement of the differential pinion gears is seen.
12. Insert Handle T83T-4205-A 1 into the bore of the
differential pinion shaft and rotate the differential
case. Continue this until the pinion gears can be
removed through the large openings in the
differential case.
HANDLE
T83T-4205-A1
E5851-C
8. lighten the forcing screw to move the differential

side gears away from the differential pinion gears
and relieve the normal loaded condition.
9. Using a piece of o. 762mm (0.030 inch) thick shim
or gauge stock, push out the differential pinion
thrust washers located behind the differential
pinion gears.
E5852-C
13. Retain the top differential side gear and

differential clutch pack in the differential case by
hand and remove the forcing screw.
ALL RIGHTS RESERVED
14. Continue to hold tf!le differential side gear and 2. Prelubricate the thrust face of the differential side
differential clutch pack and remove the gear gears and assemble the clutch plates and clutch
rotating tool. discs to the splines of differential side gears,
15. Remove the top differential side gear and prelubricating each part with Axle Lubricant
differential clutch pack. Keep the stack of clutch F 1TZ-19580-A (WSL-M2C 191-A) or with
plates and clutch discs in exact order. Additive Friction Modifier C8AZ-19B546-A or
equivalent friction modifier lubricant meeting Ford
specification EST-M2C 118-A, both stacks.
3. Assemble the retainer clips to the ears of the
clutch plates. Make sure both clips are
completely assembled or seated onto the ears of
the clutch plates.
4. NOTE: To prevent the differential clutch pack
from falling out of the differential case, hold in
place by hand while repositioning the differential
case on a bench.
Assemble the differential clutch pack and
differential side gear into the differential case.
Make sure the differential clutch pack stays
assembled to the splines of differential side gear, .
and the retainer clips are completely seated into
the pockets of differential case.
5. Reposition the differential case on the bench.
Assemble the Step Plate T83T-4205-A4 into
bottom side gear bore. Apply a small amount of
ESA-M 1C75-8 into the centering hole of the step
plate.
16. Turn differential case so the flange or ring gear 6. Assemble the other differential clutch pack and
side is up. Ease the step plate, differential side differential side gear. Make sure the differential
gear and differential clutch pack out of the clutch pack stays assembled to the splines of
differential case. differential side gear, and the retainer clips are
17. Remove the retainer clips from both differential completely seated into the pockets of differential
clutch packs to allow separation of the clutch case.
discs and clutch plates for cleaning and 7. Install Forcing Nut T83T-4205-A2 to top of the
inspection. differential side gear.
18. Inspect the clutch plates and clutch discs for 8. Hold the differential side gear in position by hand.
cracks, excessive wear, and distortion. If one or Insert Forcing Screw T83T-4205-A3 down
more of the clutch plates or clutch discs needs through the top of the differential case, and
replacing, replace entire stack of clutch plates. thread forcing nut on the screw. The tip of the
Inspect all other parts and replace any worn or forcing screw must contact the step plate.
damaged part. 9. With tools assembled to the differential case,
19. Inspect the surfaces of the differential pinion shaft position the differential case onto the axle shaft
and the ramp surfaces on the differential case for (as a holding fixture) by aligning the splines of the
excessive wear or pitting. differential side gear with those of the axle shaft.
20. Inspect the teeth on the differential side gears 10. Position both differential pinion gears opposite
and differential pinion gears. one another through the openings in the
differential case. Align holes of the differential
Assembly pinion gears with each other. Hold the differential
1. NOTE: Always replace the entire rear axle disc pinion gears in place by hand.
and plate kits (4880) even if only one component 11. Tighten the forcing screw so the differential side
requires it. gears move away from the differential pinion
Refer to illustrations used during disassembly for gears and relieve the loaded condition.
guidance in assembly operations. 12. While holding th~ differential pinion gears in place,
Install the differential clutch packs, differential insert Handle T83T-4205-A 1 into the hole of
side gears and thrust washers. Assemble in differential pinion shaft in the differential case. Pull
exactly the same order. on the handle rotating differential case allowing
the differential pinion gears to rotate and enter
into the differential case.
ALL RIGHTS RESERVED
13. Adjust the forcing screw by very slightly Metric fastener strength can be identified with the
loosening or tightening until the required load is class identification embossed on the head of each
applied to allow the differential side gears and fastener. Increasing numbers represent increasing
differential pinion gears to rotate. strength.
14. Rotate the differential case until the holes of both
differential pinion gears are aligned with those of
the differential case.
Prelubricate both sides of the differential pinion
~~~
thrust washers with the specified lubricant,
Hypoid Gear Lubricant F1TZ-19580-A or
~~CO
WSL-M2C 191-A.
15. CAUTION: Do not overtighten the forcing
screw. Overtightening the forcing screw may GRADE 5 GRADE 7 GRADE 8 GRADE 9
damage the differential clutch pack. (HIGH STRENGTH
APPLICATIONS)
Apply torque to the forcing screw for clearance to
assemble the differential pinion thrust washers. CUSTOMARY (INCH) BOLTS
16. NOTE: During assembly, be sure the holes of the
differential pinion thrust washers and differential
pinion gears are lined up exactly with those of the
differential case.
Assemble differential pinion thrust washers into
the differential case. Use a very small
screwdriver to push the washers into place.
17. Remove the forcing screw, forcing nut, handle,
GGGO METRIC BOLTS
E9237-B
and step plate.
18. Install the differential pinion shaft in the differential
case. Install the differential pinion shaft lock pin. SPECIAL SERVICE TOOLS/EQUIPMENT
19. Install the ring gear to the differential case.
lighten new attaching bolts to specification.
Refer to Specifications in this section. Tool Number/
T83T-4205-A
SPECIFICATIONS Limited Slip Differential Tool
~
T83T-4205-A 1
Driver Handle
TORQUE SPECIFICATIONS T83T-4205-A2
Forcing Nut T83T-4205-A
T83T-4205-A3
Pinion Shaft Nut 217-271 160-200 Forcing Screw
T83T-4205-A4
Differential Bearing Cap Bolts 109-122 80-90
Step Plate
Ring Gear Attaching Bolts Grade 9 95-122 70-90
Oil Filler Plug - 1/4 Inch Recess 20-30 15-24
Drive
U-Joint Bolts 21-27 15-20
Carrier to Axle Arm 54 40
WARNING: FASTENERS OF A LOWER GRADE OR

CLASS THAT ARE TIGHTENED TO THE TORQUE
SPECIFICATIONS OF A HIGHER GRADE OR
CLASS FASTENER (E.G., GRADE 5 FASTENER
TIGHTENED TO THE TORQUE SPECIFICATIONS
OF A GRADE 8 FASTENER) MAY RESULT IN
COMPONENT FAILURE.
Inch grade fasteners can be identified by the radial
lines embossed on the head of the fastener and will
correspond to the fastener strength by two lines less
than actual grade (Le., grade 8 fastener will display 6
radial lines on the head).
ALL RIGHTS RESERVED
05-02G-1 Axle, Integral Carrier, 8.8-lnch Ring Gear 05-02G-1
SECTION 05-02G Axle, Integral Carrier, a.a-Inch Ring

Gear
VEHICLE APPLiCATION ..............•...•......••....••....•......05-02G·1 DISASSEMBLY AND ASSEMBLY (Cont'd.)
DESCRIPTION AND OPERATION Sensor, Anti-Lock Brake, Instaliation.•••.••••....•OS·02G-37
Brake System, Anti-Lock, Rear •.•..••.••.•••...••.•....••.OS·02G-2 Wheel Bearing and Oil Seal
Description .•...•...•.....•.•.....•..•...•.............•.••........•OS-02G·1 Installation •.•....•.........•....•.•••.••••.•.••......•..•.•OS-02G-29
Noise Acceptability ...•.....•..•.•..•.•...•.•.•••....•..•..•.•••OS·02G-4 Axle Disassembly .........•.•..••..••....•...•.............••..OS-02G-19
Operation..•..•....•••...•..•.....••.....•...........•.•...•..•.....•OS-02G·2 Axle Shaft Removal ••...•..•......••••..•••••...•..•.•...•.OS·02G-20
DIAGNOSIS AND TESTING Companion Flange and Pinion Oil Seal
Axle, Integral Carrier .........•....•............•....•...•..••••OS·02G-4 Removal ....••.....•.....•........•.••.......••...••..•......OS·02G-20
REMOVAL AND INSTALLATION Differential Case Removal •••....•.•..•....•..•.•.•••••.OS-02G-21
Axle Housing •...•....•..•.•............•.•..•.•..•.............••OS-02G-1S Differential Case Runout Check •.••...............•.05-02G-23
Axle Shaft ...•.•.•...••...•.•........•.•.••••..•......•.•...••.......OS·02G·4 Drive Pinion Removal .•.•..•.•.•...•.•.•.....•..••.....•.•05-02G-23
Axle Vent .•.••...•....•.••..•••••..•.•.•...••••.•••••••...•••••••••OS-02G-19 Pinion Bearing Cup Removal •••••••••••...••••••...•••OS·02G-23
Companion Flange and / or Pinion Seal, Rear Wheel Bearing and Oil Seal Removal..••..••.....••OS·02G-21
Axle .•......•.......•••..•.........•......•••...•.............•..•.OS·02G-11 CLEANING AND INSPECTION
Installation ..•.....•........••....•..•....•...•..•••..•...••.••OS-02G-13 Inspection After Disassembly of
Cover .•.........•...••....•...•.......•..•.••........••...•.•..•.....OS·02G-14 Carrier ..•.••..•..•...•.••....•..........•.......•••....•.........OS-02G-38
Seal and/or Bearing Replacement..•••..••..........•.OS·02G·10 Bearing Cups .•...•........•....•.••.•.•....•.....•.•.•.......OS-02G-38
Sensor Ring, Anti-Lock Speed ......•...•..••••..•.....•..•OS·02G·7 Carrier Housing ••.........•.•....•••••.•.•.•....••....•......OS·02G-39
DISASSEMBLY AND ASSEMBLY Companion Flange, Rear Axle •..•.•....•..•....••....OS-02G-39
Axle Assembly ..••.......•..........•..••....•.........•.••.•••.05-02G-25 Cone and Roller Assemblies ....•...•.....•............05-02G-39
Axle Shaft Installation ..••....•..........•....•.......•...05-02G-35 Differential Case ..•...............••..•......••.....•••..•..05-02G-39
Companion Flange, Rear Axle Gears .••••••.•..••••••••••••..•••••••.•••••••••...••••••....••••.OS-02G-38
Installation .........•.......•...•....•••..•..•.....•......••OS-02G·28 Sensor Ring, Anti-Lock •.•.....••.•••••.••....•.•.••......OS·02G-38
Cover Installation.......••.....•..•....•..•.•.........•.....OS-02G-36 Sensor, Anti·Lock Brake ............•.....•.....•.......05-02G-38
Differential Case Installation ..•••..•........•.•.•..•..OS-02G-30 Inspection Before Disassembly of
Drive Pinion and Pinion Seal Carrier ••...•.............•.....•.•..•..••.•....•.•.•.••..•.•.....OS·02G-37
Installation .....•........••.•.•..•.•............•....•..•...OS-02G-27 SPECIFICATIONS
Drive Pinion Shim Selection.•.•...••........•....•..••.OS·02G-2S Axle Shaft Endplay •.....•....••..•.•...••.•••..........•...•..OS·02G-39
Pinion Bearing Cup Instaliation..•.•...•...•.••.••..•.OS-02G-2S SPECIAL SERVICE TOOLS/EQUIPMENT••...........•..OS·02G-40
VEHICLE APPLICATION
F-150 and Bronco Vehicles
Description The differential case (4204) is a one-piece design with

two openings to allow for assembly of the internal
The rear axle assembly (4006) is an integral type
components and lubricant flow. The differential pinion
housing, hypoid gear design with the centerline of the
shaft (4211) is retained with a threaded lock bolt
pinion set below the centerline of the ring gear.
assembled to the differential case. The differential
The hypoid gearset consists of an B.B-inch diameter case is mounted in the rear axle housing between two
ring gear and an overhung drive pinion which is opposed differential bearings (4221) and is retained in
supported by two opposed cone and roller bearings. the housing by removable bearing caps.
Pinion bearing preload is maintained by a collapsible
The rear axle assembly is available in two models to
spacer on the drive pinion shaft and adjusted by the
accommodate tread width differences between the
pinion nut.
vehicle lines. They are similar except for minor
The rear axle housing (4010) consists of a cast center suspension bracket connections and variations in axle
section (carrier) with two steel tube assemblies and a shaft and housing tube lengths.
stamped axle housing cover (4033). The cover uses
silicone sealant as a gasket. • Differential bearing preload and ring gear backlash
are adjusted by the use of shims located between
the differential bearing cup (4222) and the rear axle
housing.

ALL RIGHTS RESERVED
• The use of a pinion depth gauge tool for drive pinion CAUTION: All F-150 Lightning vehicles and all
shim selection in conjunction with a dial indicator for regular F-150 vehicles equipped with 4.10: 1 ratio
differential case shim selection is required for Traction-Lok@ rear axles are filled with synthetic
proper gear set adjustment. rear axle lubricant. If, for any reason, the rear
• The semi~floating axle shafts (4234) are held in the axle lubricant is drained, it must be replaced with
axle housing by l)-washers positioned in a slot on 5.5 pints of F1TZ-19580-B plus 5-ounces of
the axle shaft splined end. These U-washers also fit additive friction modifier F3TZ-19B546-MA or
into a machined recess in the differential side gears equivalent meeting Ford specification
(4236) within the differential case. M2C196-A. To verify, metal 10 tag on rear axle
will read 4L10: 1.
Integral Carrier, Rear Axle Assembly

Brake System, Anti-Lock, Rear
F-150 and Bronco vehicles use the Anti-Lock Brake
System. The system features an anti-lock speed
sensor ring that is pressed on the differential case
(4204) behind the ring gear. If the anti-lock speed
sensor ring is removed, it must be discarded and
replaced with a new one. The anti-lock speed sensor
ring works in conjunction with an electronic rear brake
anti-lock sensor. This sensor is retained in a bore at
the top of the carrier housing and fastened by one bolt.
There is a space provided between the ring gear and
anti-lock speed sensor ring for measuring the ring gear
backface runout.
Operation
The rear axle drive pinion receives its power from the
engine (6007) through the transmission (7003) and
driveshaft (4602). The pinion gear rotates the
differential case (4204) through engagement with the
ring gear, which is bolted to the differential case.
Inside the differential case, two differential pinion
gears (4215) are mounted on the differential pinion Part
shaft (4211) which is pinned (with lock bolt) to the Item Number Description
differential case. These pinion gears are engaged with 1 4662 Collapsible Spacer
the differential side gears (4236), to which the axle 2 4236 Differential Side Gear
shafts (4234) are splined. Therefore, as the 3 4204 Differential Case
differential case turns, it rotates the axle shafts and 4 4B409 Anti-Lock Speed Sensor
rear wheels. When conditions require one wheel and Ring
axle shaft to rotate faster than the other, the faster 5 4067 Differential Bearing Shim
turning differential side gear causes the differential
6 4221 Differential Bearing
pinion gear to roll on the slower turning differential side
gear to allow differential action between the two axle 7 4209 Hypoid Gearset
shafts. 8 390943-S 100 Fill Plug with Magnet
9 4630 Drive Pinion Bearing Cone
and Roller
10 4621 Front Pinion Bearing Cone
and Roller
11 4676 Pinion Seal
12 4851 Rear Axle Companion Flange
(Circular)
(15-30 Lb-Ft)

ALL RIGHTS RESERVED
OS-02G-3 Axle, Integral Carrier, 8.a-lnch Ring Gear OS-02G-3
DESCRIPTIO~ AND OPERATION (Continued)
~ Integral Carrier, Disassembled View

ALL RIGHTS RESERVED
OS-02G-4 Axle, Integral Carrier, a.a-Inch Ring Gear OS-02G-4
Part Part
1 4346 Axle Housing Cover Bolt 26 4022 Brake Junction Block
2 4033 Axle Housing Cover 27 390943-S 100 Filler Plug
3 - Rear Axle Identification Tag 28 4616 Front Drive Pinion Bearing
(Part of 4002) Cup
4 4230 Differential Pinion Thrust 29 389546-S 100 Pinion Nut
Washer 30 4851 Rear Axle Companion Flange
5 4215 Differential Pinion Gear 31 4676 Pinion Seal
6 4N237 U-Washer 32 4670 Oil Slinger
7 4211 Differential Pinion Shaft 33 4621 Front Pinion Bearing Cone
8 4236 Differential Side Gear and Roller
9 4228 Differential Side Gear Thrust 34 4662 Collapsible Spacer
Washer 35 2251 Rear Axle Brake Line Clip
10 4241 Lock Bolt 36 2209/2210 Brake Assembly
11 4221 Differential Bearing 37 34449-S312 Brake Backing Plate Nut
12 4067 Differential Bearing Shim 38 2248 Bolt
13 4222 Differential Bearing Cup 39 2092 Spring Push-On Nut
14 4216 Ring Gear Bolt 40 4234 Axle Shaft Assembly
15 4204 Differential Case 41 1225 Rear Wheel Bearing
16 4B409 Anti-Lock Speed Sensor 42 1177 Inner Wheel Bearing Oil Seal
Ring 43 1107 Wheel Bolt
17 4209 Ring Gear and Pinion 44 1126 Brake Drum
18 4663 Pinion Shim 45 - Differential Carrier (Part of
19 4630 Rear Pinion Bearing Cone 4010) (Lightning Truck Only)
and Roller A - Tighten to 38-52 N·m
20 4628 Rear Pinion Bearing Cup (28-38 Lb-Ft)
21 - Bearing Cap and Bolt 8 - Tighten to 20-40 N·m
(Part of 4010) (15-30 Lb-Ft)
22 2L373 RABS Sensor C - Tighten to 95-115 N·m
22 4346 Bolt (70-85 Lb-Ft)
23 4A001 Rear Axle Housing Vent D - Tighten to 28-54 N·m
Hose, F-150 and Bronco (20-40 Lb-Ft)
24 4022 Rear Axle Housing Vent E - Tighten to 34-40 N·m
25 4010 Rear Axle Housing (25-30 Lb-Ft)
(Continued)

Noise Acceptability
A gear-driven unit (especially on a drive axle) will Axle Shaft
produce a certain amount of noise. Some noise is
acceptable and may be audible at certain speeds or Removal
under various driving conditions, as on a newly paved 1. Raise vehicle and install safety stands. Remove
blacktop road. The slight noise is in no way detrimental rear wheel and tire. Refer to Section 04-04 in the
to operation of the rear axle and must be considered Body, Chassis Manual. Remove rear brake drum
normal. (1126). Refer to Section 06-02 in the Body,
Vehicles equipped with a limited slip (Traction-Lok@ ) Chassis Manual.
differential may exhibit a slight stick-slip noise 2. Clean all dirt from the area of the axle housing
(chatter) on tight turns after extended highway driving. cover (4033) with a wire brush.
This is considered acceptable and has no detrimental
effect.
)IAGNOSIS AND TESTING
Axle, Integral Carrier


ALL RIGHTS RESERVED
05-02G-5 Axle, Integral Carrier, a.a-Inch Ring Gear 05-02G-5
3. Drain rear axle lubricant by loosening axle

housing cover bolts. Remove bolts and axle
housing cover.
AXLE
HOUSING
COVER
4033
DIFFERENTIAL
PINION SHAFT
4211
E4708-C
5. NOTE: When removing the U-washer, use care

not to lose or damage the rubber a-ring which is
in the axle shaft groove under the U-washer. The
a-ring is used to hold the U-washer in position
until the axle shafts (4234) are pulled back in
DRAIN place at reassembly.
PAN E9813-A
Push the flanged end of the axle shafts inboard
and remove the U-washer from the button end of
4. CAUTION: Install new differential pinion shaft each axle shaft.
lock bolt after removal. If new bolt is not
available, thoroughly clean threads of used
bolt and coat with Stud and Bearing Mount
O-RING
EOAZ-19554-BA or equivalent meeting Ford
specification WSK-M2G349-A 1 before
installation.
Remove lock bolt and differential pinion shaft
(4211).
U-WASHER
4N237
E4709-D

ALL RIGHTS RESERVED
6. Remove the axle shaft from the rear axle housing

(4010), being careful not to damage the inner
wheel bearing oil seal (1177). O-RING
E4760-1B
U-WASHER
4N237
7. To replace the rear wheel bearing (1225) and / or
inner wheel bearing oil seal, refer to Seal and / or E4709-D
Bearing Replacement in this section.
Installation 3. Position the differential pinion shaft through the
differential case (4204) and differential pinion
1. Slide the axle shafts into place in the rear axle gear (4215), aligning the hole in the differential
housing. Use care so that the splines or any pinion shaft with the bolt hole. Apply Stud and
portion of the axle shafts do not damage the oil Bearing Mount EOAZ-19554-BA or equivalent
seals. Push the axle shafts inboard enough to meeting Ford specification WSK-M2G315-A to
allow installation of the U-washers. the lock bolt threads. Install lock bolt and tighten
2. NOTE: A rubber a-ring is used to hold the to 20-40 N·m (15-30 Ib-ft).
U-washer in position on the axle shaft. Be sure
that the O-ring is in the groove at the button end
NOTE: The bottom end of the axle shaft with the
4. 10 ratio F-150 will have splines around the
perimeter matching the long shaft splines. Use
extra care to install that design axle shaft into the
side gear splines.
Install the U-washers on the button end of the axle
shafts and pull the axle shafts outboard so that
the shaft lock seats in the counterbore of the
differential side gear (4236).
LOCK BOLT
4241
DIFFERENTIAL
PINION SHAFT
421'
E4708-C
4. Install rear axle housing cover and add lubricant.

Refer to Cover Installation in this section.
5. Install rear brake drum. Refer to Section 06-02 in
the Body, Chassis Manual.
6. Install rear wheel and tire. Refer to Section 04-04
in the Body, Chassis Manual.

ALL RIGHTS RESERVED
7. Remove safety stands, lower the vehicle, and

road test.
Sensor Ring, Anti-Lock Speed

Removal
1. Raise vehicle and install safety stands.
2. Remove rear wheels and tires. Refer to Section
04-04 in the Body, Chassis Manual.
3. Remove rear brake drums (1126). Refer to
Section 06-02 in the Body, Chassis Manual.
4. Remove rear axle housing cover (4033). Refer to
Cover Removal in this section.
5. Remove both rear axle shafts (4234). Refer to
Axle Shaft Removal in this section.
6. CAUTION: Bearing caps MUST NOT be
interchanged or rotated.
Mark one differential bearing cap to make sure E4761-B
the caps will be installed in their original locations
and positions with triangles pointing outboard. 9. Remove the bolts that attach the ring gear to the
differential case. Remove the ring gear from the
differential case by striking at alternate holes
around the gear. Use a punch that is small enough
to hit the bottom of the tapped holes and not
damage the threads. Use care to prevent
damage to ring gear teeth. Support the ring gear
while removing the bolts so that the ring gear
doesn't fall and nick any teeth.
ANTI-LOCK
SPEED SENSOR
RING
48409
E4707-1C
7. NOTE: The direction and location of triangles on

bearing caps must be noted. When reassembled
the triangles must be pointing in the same
direction (outboard) as before removal.
Loosen the differential bearing cap bolts and
bearing caps.
8. CAUTION: When using the pry bar in the
following step, place a wood block between
the pry bar and the axle housing to protect
the differential carrier face from damage.
E721 0-0
Pry the differential case (4204), differential
bearing cups and shims out until they are loose in
the bearing caps. Remove the bearing caps and
remove the differential case from the carrier.

ALL RIGHTS RESERVED
10. Remove the anti-lock speed sensor ring with a

soft-faced hammer. Discard anti-lock speed
sensor ring. Once removed, the anti-lock speed
sensor ring cannot be reused. A new anti-lock
speed sensor ring must be installed.
E7206-C
Installation
1. CAUTION: Extreme care should be taken not
to scratch, dent, chip or otherwise cause
Align tab on anti-lock speed sensor ring with slot
in differential case. Tab on anti-lock speed sensor
ring MUST be aligned with slot in differential
case. Start two ring gear bolts through the
differential case into the ring gear to make sure of
case-to-ring gear bolt hole alignment.
VIEW A
E7207-D
Part
1 3L222 Ring Gear Bolts
2 48409 Anti-Lock Speed Sensor
Ring
3 4209 Ring Gear
Ring Tab (Part of 48409)
(Part of 4204)

ALL RIGHTS RESERVED
2. Press the anti-lock speed sensor ring on the

differential case using the ring gear as a pilot.
Apply Stud and Bearing Mount EOAZ-19554-BA 6.73MM
or equivalent meeting Ford specification (0.265 INCH)
WSK-M2G349-A 1 to ring gear bolts. SHIM-4067
6. NOTE: Triangles on bearing cups must point

outboard.
NOTE: When installing, apply pressure towards
left side to make sure that the left bearing cup is
seated.
3. Install ring gear bolts and tighten to 95-115 N·m Install left bearing cap and tighten bolts
(70-85Ib-ft). finger-tight.
4. Install differential case in carrier.
DIFFERENTIAL
5. Install a 6.73mm (0.265 inch) shim on left side.

ALL RIGHTS RESERVED
05-02G-10 Axle, Integral Carrier, S.S-Inch Ring Gear 05-02G-10
7. Install shim to right side while applying pressure Seal and/ or Bearing Replacement
toward left side.
Axle Wheel Bearing Puller T83T-1225-A
Axle Wheel Bearing Replacer T83T-1225-B
Hub Seal Replacer T83T-1175-B
Removal
1. Rai$e vehicle and install safety stands. Remove
rear wheel and tire. Refer to Section 04-04 in the
Body, Chassis Manual. Remove rear brake drum
(1126). Refer to Section 06-02 in the Body,
Chassis Manual.
2. Remove rear axle housing cover (4033) and rear
axle shafts (4234). Refer to Axle Shaft Removal
and Installation in this section.
3. NOTE: If inner wheel bearing oil seal (1177) is
8. Install right side bearing cap and tighten bolts to leaking, check the axle housing vent. If the rear
95-115N.m (70-85Ib-ft). axle housing vent (4022) is plugged with dirt or
debris, it will cause pressure buildup in the rear
axle housjng (4010) which can lead to seal leaks.
Using Impact Slide Hammer T50T-1 OO-A and Axle
Wheel Bearing Puller T83T-1225-A, insert into the
bore as shown and position behind the rear wheel
bearing (1225) so the tangs on the tool engage
the bearing outer race. Remove the rear wheel
bearing and inner wheel bearing oil seal as a unit,
using the slide hammer tool. Inspect rear wheel
bearing for wear. Replace as necessary.
AXLE WHEEL
BEARING PULLER
T83T-1225-A
9. Check backlash and runout. Adjust if necessary.

Refer to Differential Case Installation in this
section.
10. Install both rear axle shafts. Refer to Axle Shaft
11. Install rear axle housing cover. Refer to Cover
12. Install rear brake drums. Refer to Section 06-02 in
13. Install rear wheels and tires. Refer to Section
IMPACT SLIDE HAMMER
14. Check and add fluid (rear axle). TSOT-1QO-A
15. Remove safety stands and lower vehicle.
16. Road test. AXLE WHEEL
BEARING PULLER
T83T-1225-A

ALL RIGHTS RESERVED
05·02G-11 Axle, Integral Carrier, S.S-Inch Ring Gear 05-02G-11
REMOVAL AND INSTALLATION' (Continued)
Installation
bearing or inner wheel bearing oil seal
assembly without the proper tool may result
in a bearing or seal failure. If inner wheel
beari.,g oil seal becomes cocked In the bore
during installation, remove inner wheel
bearing oil seal and Install a new inner wheel
bearing oil seal. .
Lubricate the new rear wheel bearing with rear
axle lubricant and install the rear wheel bearing
into the housing bore using Axle Wheel Bearing
Replacer 1831-1225-B.
AXLE WHEEL
BEARING REPLACER
T83T-1225-B
E9815·A
3. Install axle shaft and rear axle housing cover.

Refer to Axle Shaft Removal and Installation in
this section. Check and fill rear axle with fluid.
4. Install rear brake drum. Refer to Section 06-02 in
the Body, Chassis Manual. Install rear wheel and
tire. Refer to Section 04-04 in the Body, Chassis
Manual. Remove safety stands and lower vehicle.
5. Road test.
I
-'
E9814-A Companion Flange and/or Pinion Seal, Rear

Axle
2. Coat the lips of the inner wheel bearing oil seal
with Premium Long-Life Grease XG-1-C or -K or SPECIAL SERVICE TOOL(S) REQUIRED
equivalent meeting Ford specification Description Tool Number
ESA-M1C75-B and install the inner wheel bearing
oil seal using Hub Seal Replacer 1831-1175-8. Companion Flange Holding Tool T78P-4851-A
Puller - Differential Side Bearing T77F-4220-B 1
Removal
1. N01E: If pinion seal is leaking, check the rear
axle housing vent (4022). If the axle housing vent
is plugged with dirt or debris it will cause pressure
buildup in the rear axle housing (4010) which can
lead to pinion seal problems.
CAUTION: This operation disturbs the pinion
bearing preload, and this preload must be
carefully reset when assembling.
Raise the vehicle and install safety stands.
Remove the rear wheels and brake drums (1126)
to prevent brake drag during drive pinion bearing
preload adjustment.
1995 F-150, F-250, F-350, Bronco. F-Super Duty ~owertrain. Drivetrain July 196

ALL RIGHTS RESERVED
2. Mark the driveshaft axle end flange and the rear 4. While holding the rear axle companion flange with
axle companion flange to make sure the Companion Flange Holding Tool T78P-4851-A,
driveshaft will be properly positioned during remove the pinion nut.
assembly. Disconnect the driveshaft (4602) from
the rear axle companion flange. Remove the
driveshaft from the extension housing (7A039). COMPANION FLANGE
Install an oil seal replacer tool in the extension HOLDING TOOL
T78P-4851-A
housing to prevent oil leakage.
5. Clean the area around the pinion seal. Place a

drain pan under the pinion seal, or raise the front
of the vehicle higher than the rear.
6. Mark the rear axle companion flange in relation to
drive pinion shaft so rear axle companion flange
3. Install an inch-pound torque wrench on the pinion can be reinstalled in the same position.
nut. Record the torque required to maintain
rotation of the pinion through several revolutions. MARK FLANGE IN
RELATION TO PINION
F2671·B
TORQUE WRENCH
N·m (LB-IN) F2669-F

ALL RIGHTS RESERVED
7. Using Puller - Differential Side Bearing 9. CAUTION: Installation without the proper tool
T77F-4220-B 1, remove the rear axle companion may result in seal failure. If pinion seal
flange. Place drain pan under axle pinion nose. becomes misaligned during Installation,
remove it and install new one.
PULLER-DIFFERENTIAL
Clean the seat surface of pinion seal. Install the
SIDE BEARING pinion seal in the housing bore using Pinion Seal
n7F-4220-81 Replacer T83T-4676-A. Coat the lips of the seal
with Premium long-Life Grease XG-1-C or -K or
ESA-M1C75-B.
PINION SEAL
REPLACER
T83T-4676-A
E4892-C
8. Pry up on metal flange of pinion seal. Install E5891-O

gripping pliers and strike with hammer until pinion
seal is removed.
Installation
1. Apply a small amount of lubricant to the rear axle
companion flange splines.
2. NOTE: If a new rear axle companion flange is
being installed, disregard the scribe mark on the
pinion shaft.
CAUTION: The rear axle companion flange
must never be hammered on or installed with
power tools.
Align the mark on the rear axle companion flange
with the mark on the pinion shaft.
3. Install the rear axle companion flange using
Companion Flange Replacer TOOL-4858-E or
equivalent. Install a new pinion nut on the pinion
stem.

ALL RIGHTS RESERVED
4. Hold the rear axle companion flange with 8. Remove the oil seal replacer tool from the
Companion Flange Holding Tool T78P-4851-A extension housing of the transmission. Install the
while tightening the pinion nut. driveshaft into the extension housing. Align the
scribe marks on the rear axle companion flange
and driveshaft end flange. Install the attaching
bolts and tighten to 95-128 N·m (70-95Ib-ft).
COMPANION FLANGE
HOLDING TOOL 9. Check and add rear axle fluid.
T78P-4851·A
10. Install rear brake drums. Refer to Section 06-02 in
11. Install rear wheels and tires. Refer to Section
12. Remove safety stands and lower vehicle. Road
test.
Cover
E48IO-D Removal
5. Tighten the pinion nut, rotating the pinion 2. Clean all dirt from the area of axle housing cover
occasionally to make sure pinion bearing cone (4033) with a wire brush.
and roller assemblies seat properly. Take
3. Loosen axle housing cover and drain lubricant
frequent torque preload readings until the original
from axle housing. Remove axle housing cover.
recorded preload reading is obtained.
6. If the original recorded preload is lower than AXLE
specification (used bearings: .9-1.5 N·m [8-14 HOUSING
Ib-in] new bearings: 1.8-3.3 N·m [ 16-29 Ib-in]) COVER
tighten to specification. If the preload is higher 4033
than specification tighten to original reading as
recorded in Step 3 of the removal procedure.
7. Under no circumstances should the pinion nut be
DRAIN
PAN
E9813-A
E4900-E

ALL RIGHTS RESERVED
Installation 4. Add lubricant through the filler hole until the

1. CAUTION: Make sure machined surfaces on lubricant level is 1/ 4 to 9/ 16 inch below the
both axle housing cover and carrier are clean bottom of the filler hole with the axle in the running
and free of oil before Installing the new position. All F-150 Lightning vehicles and regular
silicone sealant. Inside of rear axle (4001) F-150 vehicles and Bronco vehicles equipped
must be covered when cleaning the with 4.10: Ratio Traction-Lok@ differentials, use
machined surface to prevent contamination. Motorcraft Synthetic Rear Axle Lubricant
F 1TZ-19580-8 or equivalent meeting Ford
Clean the gasket mating surface of the rear axle specification WSL-M2C192-A, plus 148ml (5
carrier casting and axle housing cover. ounces) of additive friction modifier
2. Apply a new continuous bead of Silicone Rubber F3TZ-19B546-MA or equivalent meeting Ford
D6AZ-19562-AA or -BA or equivalent meeting specification WSP-M2C197-A. Vehicles not
Ford specifications ESB-M4G92-A and equipped with a 4.10: ratio axle use Motorcraft
ESE-M4G 195-A to the new axle housing cover. Synthetic Rear Axle Lubricant XV-80W90-QL or
WSP-M2C197-A, plus 57 grams (two ounces) of
Additive Friction Modifier (for Traction-Lok@
axles) F3TZ-198546-MA or equivalent meeting
Ford specification WSP-M2C 196-A. See metal
service identification tag located Oll rear axle
housing cover for correct ratio. Install the filler
plug and tighten to 20-40 N·m (15-30 Ib-ft).
5. Remove safety stands. Lower vehicle and road
test.
FM'..A
3. NOTE: Axle housing cover assembly must be

installed within 15 minutes of application of the
silicone or new sealant must be applied. If time
permits, allow one hour before filling with lubricant
to make sure silicone sealant has properly cured.
Install axle housing cover and tighten bolts to
38-52 N·m (28-38Ib-ft) as shown. Tighten the
cover bolts in a cross-wise pattern to prevent
axle housing cover from getting cocked.
Axle Housing
Companion Flange Holding Tool T78P-4851-A
Puller - Differential Side Gear T77F-4220-B1
Pinion Bearing Cone Remover T71 P-4621-B
Pinion Depth Gauge T79P-4020-A
Pinion Bearing Cup Replacer T67P-4616-A
Pinion Bearing Cone Replacer T53T-4621-C
Shim Driver T85L-4067-AH
E~1'1·D

ALL RIGHTS RESERVED
Removal
1. NOTE: This procedure includes removal
(transfer) of differential ring gear and pinion
(4209).
Raise vehicle and install safety stands. Remove
rear wheels and tires. Refer to Section 04-04 in
2. Remove brake drums (1126). Refer to Section
3. Remove driveshaft (4602), companion flange,
and pinion seal. Refer to Companion Flange and
Pinion Oil Seal Removal in this section.
4. Remove rear axle shafts (4234). Refer to Axle
Shaft Removal and Installation in this section.
5. Perform inspection of rear carrier. Refer to
E4763-D
Inspection Before Disassembly of Carrier in this
section.
6. CAUTION: Bearing caps MUST NOT be following step, place a wood block between
interchanged or rotated. the pry bar and the axle housing to protect
Mark one differential bearing cap to make sure the differential carrier face from damage.
the caps will be installed in their original locations Pry the differential case (4204), differential
and positions with triangles pointing outboard. bearing cups (4222) and differential bearing
shims (4067) out until they are loose in the
bearing caps. Remove the bearing caps and
remove the differential case from the carrier.
h707·1C

bearing caps. E4761-B
9. NOTE: If replacing the rear axle housing (4010),

it may be necessary to install new pinion bearings
and cups (front and rear). Refer to Pinion Bearing
Cup Removal and Installation in this section.
With a soft-faced hammer, drive the pinion out of
the front differential pinion bearing and remove it
through the rear of the differential carrier.
Remove front differential pinion bearing (4621).

ALL RIGHTS RESERVED
10. Remove the rear pinion bearing cone and roller,

using the Pinion Bearing Cone Remover
T71P-4621.
BRAKE AND
FUEL LINE
TUBING
2269
E4728-C
14. Disengage the brake and fuel line tubing (2269)

from the rear axle brake line clips (2251) that
E4732-C retain the brake and fuel line tubing to the axle
housing and carrier.
11. Measure the pinion shim, which is found under the
rear pinion bearing cone and roller, with a
micrometer and record the thickness (as a
reference to be compared to the pinion shim
gauge reading prior to installing the rear pinion
bearing, cone and roller).
12. Remove the four retaining nuts from each brake
backing plate (2211) and wire the brake backing
plates to the underbody.
E4728-B
15. Remove the hydraulic brake hose junction block

from the axle housing. Do not open the brake
and fuel line tubing.
BRAKE
BACKING
PLATE NUT
(4 REQ'D)
13. Disconnect the rear axle hose (4090) from the

rear axle housing vent (4022) and the rear axle
housing vent from the rear axle housing.
E8835-B

ALL RIGHTS RESERVED
16. Support the rear axle housing on a jack, and then

remove the U-bolt nuts. Remove the U-bolts and
plates.
U-BOLTS
E47»C
2. Connect the shock absorber lower bolts to the

U-BOLTS mounting bracket on the rear axle housing. Install
E47»C the attaching nuts and tighten to the
specifications listed in Section 04-02 in the Body,
17. Remove both stabilizer U-bolts and nuts. Remove Chassis Manual. Remove support jack from under
stabilizer bar bracket assemblies. Refer to axle housing.
18. Disconnect the shock absorber lower bolts from
the mounting brackets on the axle housing.
SHOCK ABSORBER
LOWER BOLT
AND NUT
E4729·1A
SHOCK ABSORBER 3. Install stabilizer bar brackets, bar, and U-bolts.

LOWER BOLT
AND NUT Tighten nuts to 40-57 N·m (30-40 Ib-ft). Refer to
E4729·1A Section 04-02.
19. Remove the rear axle housing from the vehicle. 4. Insert the rear axle housing vent into the brake
junction block and position the assembly over the
Installation
housing vent hole. Hand start the rear axle
1. Raise the rear axle housing into position so that housing vent and tighten.
the rear spring caps and plates (5796) can be
installed. Tighten the U-bolts to the specification
listed in Section 04-02 in the Body, Chassis
Manual (specifications vary depending on the
vehicle).
E4728·B
5. Position the brake and fuel line tubing to the rear

axle housing and secure with the rear axle brake
line clips at the right hand axle tube and rear axle
housing vent through the brake junction block.

ALL RIGHTS RESERVED
OS-02G-19 Axle, Integral Carrier, 8.8-lnch Ring Gear 05-02G-19
,REMOVAL AND INSTALLATION (Continued)
6. Install the brake backing plates on the axle 2. Disconnect rear axle hose (4090) from the rear
housing flanges (no gaskets required). lighten axle housing vent (4022).
the attaching nuts to 28-54 N·m (20-40 Ib-ft). 3. Remove rear axle housing vent from rear axle
housing (4010).
BRAKE AND
FUEL LINE
TUBING
2269
BRAKE
BACKING
PLATE NUT
(4 REQ'D)
E9816-A
E4726-C
7. Perform inspection of rear carrier. Refer to
Inspection After Disassembly of Carrier in this
section. Installation
8. Check and set pinion depth. Install pinion, 1. Install rear axle housing vent to rear axle. lighten
bearings, oil seal, rear axle companion flange. to 20-34 N·m (15-25Ib-ft).
Refer to Companion Flange and / or Pinion Seal, 2. Connect rear axle hose to rear axle housing vent.
Rear Axle, Removal and Installation in this section
3. Check and add rear axle fluid if necessary.
and set pinion torque preload. Refer to Drive
Pinion Shim Selection in this section to check 4. Remove safety stands and lower vehicle.
preload and runout.
differential case (with ring gear, anti-lock speed DISASSEMBLY AND ASSEMBLY
sensor ring, differential pinion thrust washers
(4230), differential side gears, differential Axle Disassembly
bearings) in carrier. Refer to Differential Case
Installation in this section. SPECIAL SERVICE TOOL(S) REQUIRED
10. Install axle shafts. Refer to Axle Shaft Removal
and Installation in this section. If installing new Description Tool Number
axle,bearings and seals, refer to Wheel Bearing Impact Slide Hammer T50T-100-A
and Oil Seal Removal and Installation. Axle Wheel Bearing Puller T83T-1225-A
11. Install driveshaft. Refer to Rear Axle Companion Pinion Bearing Cone Remover T71P-4621-B
Flange and / or Pinion Seal, Rear Axle Installation Differential Side Bearing Remover T70P-4221-A
in this section. Differential Side Bearing Replacer T57L-4221-A2
12. Install rear axle housing cover (4033), bolts, and
add fluid. Refer to Cover Installation in this Sensor, Anti-Lock Brake, Removal
section. 1. Remove bolt. Remove rear brake anti-lock
13. Install rear brake drums. Refer to Section 06-02 in sensor.
the Body, Chassis Manual. 2. Clean axle mounting surface, using caution to
14. Install rear wheels and tires. Refer to Section prevent dirt from entering rear axle housing
04-04 in the Body, Chassis Manual. (4010).
15. Remove safety stand, and lower vehicle. 3. Observe if axle lubricant has leaked up through
core or around perimeter of rear brake anti-lock
16. Road test. sensor a-ring. Discard if leakage is present.
Axle Vent
Removal
1995 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain July 199,

ALL RIGHTS RESERVED
Companion Flange and Pinion Oil Seal Removal 4. NOTE: When removing the U-washer, use care
not to lose or damage the rubber O-ring which is
SPECIAL SERVICE TOOL(S) REQUIRED in the axle shaft groove under the U-washer. The
O-ring is used to hold the U-washer in position
Description Tool Number until the axle shafts (4234) are pulled back in
Companion Flange Holding Tool T78P-4851-P place at reassembly.
Puller - Differential Side Bearing T77F-4220-B 1 Push the flanged end of the axle shafts inboard
and remove the U-washer from the button end of
Remove driveshaft, pinion nut, rear axle companion each axle shaft.
flange and pinion seal as described in Removal and
Installation in this section. Be sure to mark driveshaft,
flange, and pinion for proper assembly.
NOTE: If pinion seal is leaking, check the rear axle O-RING
housing vent (4022). If the rear axle housing vent is
plugged with dirt or debris it will cause pressure
buildup in the axle which can lead to pinion seal
problems.
Axle Shaft Removal
1. Clean all dirt from the area of axle housing cover
(4033) with a wire brush or cloth.
2. Drain rear axle lubricant by removing the axle
housing cover. Refer to Cover, Axle Housing
Removal and Installation in this section.
3. CAUTION: Install new differential pinion shaft
lock bolt after removal. If new bolt is not
available, thoroughly clean threads of used
bolt and coat with Threadlock and Sealer,
EOAZ-19554-AA or equivalent meeting Ford U-WASHER
specification WSK-M2G351-A5 (Type II) 4N237
before installation.
E4709-D
Remove lock bolt and differential pinion shaft
(4211).
5. Remove the axle shaft from the axle housing,
being careful not to damage the inner wheel
bearing oil seal (1177).
LOCK BOLT E4760-1B

4241
DIFFERENTIAL
PINION SHAFT
4211
E4708-C

ALL RIGHTS RESERVED
~ Wheel Bearing and Oil Seal Removal

1. NOTE: If inner wheel bearing oil seal is leaking,
check the rear axle housing vent. If the rear axle
housing vent is plugged with dirt or debris, it will
cause pressure buildup in the rear axle housing
which can lead to seal leaks.
Using Impact Slide Hammer T50T-100-A and Axle
Wheel Bearing Puller T83T-1225-A insert into the
bore as shown and position behind the bearing so
the tangs on the tool engage the bearing outer
race. Remove the rear wheel bearing (1225) and
inner wheel bearing oil seal as a unit, using the
slide hammer tool.
AXLE WHEEL
BEARING PULLER
TS3T-1225-A
E4707·1C

bearing caps.
IMPACT SLIDe HAMMER

TSOT-1OQ-A
AXLE WHEEL
BEARING PULLER
T83T-1225-A
E4712-F
Differential Case Removal E4783-D
1. NOTE: Before removing the differential case

(4204), check the ring gear runout as described
in the Cleaning and Inspection portion of this
section. If ring gear runout exceeds 0.10mm
(0.004 inch), the differential case and ring gear
and pinion must be removed to perform the
differential runout check. The differential runout
check will isolate the cause of excessive ring
gear runout.
CAUTION: Bearing caps MUST NOT be
interchanged or rotated.
Mark one differential bearing cap to make sure
the caps will be installed in their original locations
and positions with triangles pointing outboard.
ALL RIGHTS RESERVED
,05-02G-22 Axle, Integral Carrier, S.S-Inch Ring Gear 05-02G-22

following step, place a wood block between
the pry bar and the rear axle housing to ANTI-LOCK
protect the differential carrier face from SPEED SENSOR
damage. RING
48409
Pry the differential case, differential bearing cups
and shims out until they are loose in the bearing
caps. Remove the bearing caps and remove the
differential case from the differential carrier.
E721 0-0
5. NOTE: The ring gear can be removed and

installed without removing the anti-lock speed
sensor ring.
On vehicles equipped with an anti-lock speed
sensor ring, remove the ring gear bolts. Remove
ring gear by striking at alternate holes around the
gear. Support the ring gear to prevent nicked
teeth.
E4781-B
6. Remove the anti-lock speed sensor ring with a
soft-faced hammer. Discard anti-lock speed
4. Remove the bolts that attach the ring gear to the
sensor ring. Once removed, the anti-lock speed
differential case. Remove the ring gear from the sensor ring cannot be reused. A new anti-lock
differential case by striking at alternate holes
speed sensor ring must be installed.
around the gear. Use a punch that is small enough
to hit the bottom of the tapped holes and not
damage the threads. Use care to prevent
damage to ring gear teeth. Support the ring gear
while removing the bolts so that the ring gear
doesn't fall and nick any teeth.
E7206-C
ALL RIGHTS RESERVED
~ Drive Pinion Removal

1. With a soft-faced hammer, drive the pinion out of
the front drive pinion bearing cup and remove it
through the rear of the differential carrier.
To remove the pinion bearing cone and roller
assembly, use the Pinion Bearing Cone Remover
T71P-4621-B as shown.
E5112-e
Differential Case Runout Check

E.732-C If the ring gear runout check (before disassembly)
exceeds specification (0. 101 mm [0.004 inch]), the
2. Measure the pinion shim, which is found under the condition may be caused by a warped ring gear, a
drive pinion bearing cone and roller, with a damaged differential case, excessively worn
micrometer and record the thickness (as a differential bearings (4221) or foreign material
reference to be compared to the shim gauge between mating surfaces (burrs, shavings, etc.). To
reading prior to installing the drive pinion bearing determine the cause of excessive runout, proceed as
cone and roller). follows:
Pinion Bearing Cup Removal 1. Remove the differential case from the rear axle
housing. (Refer to Differential Case and Drive
1. NOTE: Do not remove the drive pinion bearing Pinion Removal in this section.) Remove the bolts
cups from the carrier casting unless the drive that attach the ring gear to the differential case.
pinion bearing cups are damaged. Remove the ring gear from the differential case
If the drive pinion bearing cups are to be with a hammer and drift.
replaced, tap alternately (with a brass drift of
suitable length) on the opposite side of the drive
pinion bearing cups during removal to prevent
drive pinion bearing cups from cocking in the
casting.
1995 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain July 199,(
ALL RIGHTS RESERVED
2. Install the differential with the shims and 4. Remove the differential case from the integral
differential bearing cups (4222). lighten the carrier and remove the differential bearings from
bearing cup bolts to 95-115 N·m (70-85 Ib-ft). the differential case using Differential Side
Bearing Remover T70P-4221-A.
DIFFERENTIAL
BEARING
4221
DIFFERENTIAL
BEARING
4221
E4735-C
3. Check the runout of the differential case flange

with a Dial Indicator with Bracketry 5. NOTE: During installation, press against the
TOOL-4201-C or equivalent. If the runout is within bearing cone only.
specification (maximum O.076mm [0.003 inch]), Install new differential bearings on the case hubs
install a new ring gear and pinion. If the runout using Differential Side Bearing Replacer
exceeds specification, the ring gear is true and T57L-4221-A2 and install the differential (4026)
the concern is due to either a damaged in the carrier without the ring gear.
differential case or differential bearings. Visually
inspect the differential bearings. If differential
bearings are not damaged replace both the
differential case and differential bearings.
Recheck the runout with new parts. Visually
inspect the anti-lock speed sensor ring for
damage and replace if required.
DIAL INDICATOR
WITH BRACKETRY
TOOl-4201 -c
E4743-E
E4741-D
ALL RIGHTS RESERVED
6. Check the case runout again with the new

differential bearings. If the runout is now within
0.076mm (max. 0.003 inch), use the new
differential bearings for assembly. If the runout is
still excessive, the differential case is damaged
and should ~e replaced.
DIAL INDICATOR
WITH BRACKETRY
~.u
TOOL-4201 -C
T67P-4616-~OP
PINION BEARING
CUP REPLACER
M733-1B
Drive Pinion Shim Selection

Individual differences in machining the carrier and the
ring gear and pinion and variation in bearing widths
require a pinion shim between the drive pinion bearing
cone and roller and pinion head, in order to locate the
pinion for correct tooth contact with the ring gear.
When replacing a ring gear and pinion, the correct
shim thickness for the new ring gear and pinion to be .
installed is determined by the following procedure
using Pinion Depth Gauge T89P-4020-A.
E4741-D 1. Assemble the appropriate aligning adapter,
gauge disc and gauge block to the screw. The
gauge block must be offset 45 degrees to obtain
an accurate reading.
Axle Assembly
Pinion Bearing Cup Replacer T67P-4616-A
Pinion Depth Gauge T79P-4020-A
Axle Wheel Bearing Replacer T83T-1225-B
Hub Seal Replacer T83T-1175-B
Differential Side Bearing Replacer T57L-4221-A2
Shim Driver T85L-4067-AH
Pinion Bearing Cup Installation

1. NOTE: Do not remove the drive pinion bearing
cups from the carrier casting unless the drive
pinion bearing cups are damaged.
Install the new drive pinion bearing cups with
Pinion Bearing Cup Replacer T67P-4616-A as
shown. Make sure the drive pinion bearing cups
are properly seated in their bores. If a 0.038mm
(0.0015 inch) feeler gauge can be inserted
between a drive pinion bearing cup and the
bottom of its bore at any point around the drive
pinion bearing cup, the cup is not properly seated.
Whenever the drive pinion bearing cups are
replaced, the pinion bearing cone and roller
assembly should also be replaced.

ALL RIGHTS RESERVED
Rear Axle Pinion Depth Gauge Tool
Part Part
1 T89P-4020-A 19 Gauge Tube (3.063 In. 0.0.) 5 T76P-4020-A9 Screw
2 T76P-4020-A 10 Gauge Block (1.7 In. Thick) 6 4630 Rear Pinion Bearing Cone
3 T79P-4020-A 18 Gauge Disc and Roller
(1.1884In. Thick) 7 4621 Drive Pinion Bearing Cone
4 T76P-4020-A3 Aligning Adapter and Roller
(1.612In.0.0.) 8 T76P-4020-A 11 Handle
(Continued)
2. Place the rear drive pinion bearing cone and roller 3. Center the gauge tube into the differential bearing
(new, or used if in good condition) over the bore. Install the bearing caps and tighten the
aligning tool and insert it into the rear pinion bolts to 95-115 N·m (70-85 Ib-ft). (Caps are to be
bearing cup of the carrier. Place the front drive installed with the triangles pointing outboard.)
pinion bearing cone and roller into the pinion 4. Utilize pinion shims as the gauge for shim
bearing cup and assemble the tool handle into the selection. This will minimize errors in attempting
screw. Roll the assembly back and forth a few to stack feeler gauge stock together or simple
times to seat the bearings while tightening the addition errors in calculating correct shim
tool handle by hand. lighten the tool handle to 27 thickness.
N·m (20 Ib-ft).
Pinion shims must be flat. Do not use dirty, bent,
nicked or mutilated shims as a gauge.
GAUGE BLOCK
TI6P-4020-A10 II
E4145-18

ALL RIGHTS RESERVED
A slight drag should be felt for correct shim

selection. Do not attempt to force the pinion shim
between the gauge block and the gauge tube.
This will minimize selecting a pinion shim thicker DRIVE PINION
than required, which results in a deep tooth BEARING
contact in final assembly of integral rear axle CONE
4630
assemblies (4006).
PINION
BEARING
CONE _ _.......,..:::::~-
~~--..,...-r--
REPLACER
T53T-4621-C
E4747-D
2. Check splines on the pinion shaft to be sure they

are free of burrs. If burrs are evident, remove
them by using a fine crocus cloth. Wipe the pinion
clean.
3. Place new collapsible spacer on the pinion shaft
against the pinion stem shoulder.
Part
2 - Screw T76P-4020-A9
4 - Gauge Disc T79P-4020-A 18
5 - Gauge Block
T76P-4020-A 10
6 - Gauge Tube T89P-4020-A 19
PINION
7 - Aligning Adapter
STEM
T76P-4020-A3 SHOULDER
8 4010 Axle Housing
9 - Handle T76P-4020-A 11
Drive Pinion and Pinion Seal Installation DRIVE

PINION
1. NOTE: The same differential pinion bearing BEARING
(4630) used in the following step must be used in CONE-4630
final assembly of the axle.

NOTE: Be sure that press load is not applied to E5889-D
the bearing cage.
Place the selected pinion shims on the pinion
shaft and press the rear drive pinion bearing cone
and roller until it is firmly seated on the shaft.

ALL RIGHTS RESERVED
4. Install the front pinion bearing cone and roller and

oil slinger in the axle housing and install the pinion
seal on the Pinion Seal Replacer T83T-4676-A.
BEARING CONE AND ROLLER

4621
COLLAPSIBLE
PINION SEAL SPACER-4662
~------------REPLACER
T83T-4676-A E5876-D
E4748-B
may result in early seal failure. If pinion seal Companion Flange, Rear Axle Installation
becomes cocked during installation, remove
it and install new one. 1. Apply a small amount of lubricant to the
companion flange splines.
Clean the oil seal seat surface. Install the pinion
seal in the axle housing using Pinion Seal 2. NOTE: If a new rear axle companion flange is
Replacer T83T-4676-A. Coat the lips of the pinion being installed, disregard the scribe mark on the
seal with Premium Long-Life Grease XG-1-C or -K pinion shaft.
or equivalent meeting Ford specification NOTE: The rear axle companion flange must
ESA-M1C75-B. never be hammered on or installed with power
tools.
PINION SEAL Align the mark on the rear axle companion flange
REPLACER with the mark on the pinion shaft. Install the rear
T83T-4676-A axle companion flange using Companion Flange
Replacer TOOL-4858-E or equivalent.
3. Install a new pinion nut on the pinion stem.
4. Hold the circular rear axle companion flange with
while tightening the pinion nut (see Step 5).
COMPANION FLANGE
HOLDING TOOL
TISP-4851-A
E5891-D
6. From the rear of the rear axle housing (4010),

install the drive pinion assembly (drive pinion,
pinion shims, rear bearing cone and roller, and
collapsible spacer) into the rear axle housing.
E4890-D

ALL RIGHTS RESERVED
5. lighten the pinion nut, rotating the pinion

occasionally to make sure pinion bearing cone
AXLE WHEEL
and roller assemblies seat properly. Take BEARING REPLACER
frequent drive pinion bearing torque preload T83T-1225-B
readings until the specified preload reading is
obtained.
New Bearings: 1.8-3.3 N·m (16-29 Ib-in)
Used Bearings: .9-1.5 N·m (8-14Ib-in)
Under no circumstances should the pinion nut be
/
-./
E9814-A
2. Coat the lips of the inner wheel bearing oil seal

with Premium Long-Life Grease XG-1-C or -K or
ESA-M 1C75-B and install the inner wheel bearing
oil seal using Hub Seal Replacer T83T-1175-B.
E4900-E
Wheel Bearing and Oil Seal Installation

bearing (1225) or inner wheel bearing oil seal
(1177) assembly without the proper tool may
result in a bearing or seal failure. If inner
wheel bearing oil seal becomes cocked in
the bore during installation, remove inner
wheel bearing oil seal and install a new inner
wheel bearing oil seal.
Lubricate the new rear wheel bearing with rear
axle lubricant and install the rear wheel bearing
into the housing bore using Axle Wheel Bearing
Replacer T83T-1225-B. E9815-A
ALL RIGHTS RESERVED
Differential Case Installation

1. Install differential bearings (4221) on the hubs of
the differential case (4204) using Differential Side
Bearing Replacer T57L-4221-A2. Press against
the bearing cone only.
DIFFERENTIAL SIDE
BEARING REPLACER
T57L-4221-A2
E4743-E
2. CAUTION: Extreme care should be taken not

to scratch, chip, dent or otherwise cause
Align tab on anti-lock speed sensor ring with slot
in differential case. Tab on anti-Ioc!. speed sensor
ring MUST be aligned with slot in differential
case. Start two ring gear bolts through the
differential case into the ring gear to make sure of E7207-D
case-to-ring gear bolt hole alignment.
Part
1 3L222 Ring Gear 80lts
2 48409 Anti-Lock Speed Sensor
Ring
3 4209 Ring Gear
Ring Tab (Part of 48409)
(Part of 4204)

ALL RIGHTS RESERVED
3. Press the NEW anti-lock speed sensor ring and 5. Install a 6.73mm (0.265 inch) shim on left side.
ring gear, if removed, onto the differential case.
Apply Stud and Bearing Mount EOAZ-19554-BA
WSK-M2G349-A 1 to ring gear bolts and install. 6.73MM
lighten the bolts to 95-115 N·m (70-85 Ib-ft). (0.265 INCH)
SHIM-4067
6. NOTE: Triangles on bearing cups must point

outboard.
NOTE: When installing, apply pressure toward
left side to make sure that the left bearing cup is
seated.
differential case (with ring gear, anti-lock speed Install left bearing cap and tighten bolts
sensor ring, differential pinion thrust washers finger-tight.
(4230), differential side gears (4236), and
differential bearings) in carrier.
DIFFERENTIAL
E4751-C

ALL RIGHTS RESERVED
7. Install progressively larger shims on the right side 10. Check ring gear and pinion backlash. If backlash
until the largest shim selected can be assembled is 0.20-0.38mm (0.008-0.015 inch)
with a slight drag feel. (0.30-0.38mm [0.012-0.0 15 inch] preferred)
proceed to Step 15. If backlash is zero, go to
Step 11. If backlash is not zero, but less than
0.20mm (0.008 inch), or more than 0.38mm
(0.015 inch), then go to Step 12.
DIAL INDICATOR
WITH BRACKETRY
TOOl-4201-C
8. Install right side bearing cap and tighten bolts to

95-115 N·m (70-85Ib-ft).
E4755-F
11. If a zero backlash condition occurs, add 0.5mm

(0.020 inch) to the right side and subtract O.5mm
(0.020 inch) from the left side to allow for a
backlash reading.
SUBTRACT
0.5 MM (0.020 IN.)
9. Rotate assembly to make sure it rotates freely.
E4756-B

ALL RIGHTS RESERVED
12. Recheck backlash. See Step 13 if backlash is not 13. If backlash is not to specification, correct
within specification. Backlash specification: backlash by increasing thickness of one shim and
0.20..0.38mm (0.008..0.015 inch) (0.30..0.38mm decreasing thickness of the other by the same
[0.012-0.0 15 inch] preferred). amount. Refer to chart for approximate shim
If backlash is within specification, go to Step 14. change.
DIAL INDICATOR
WITH BRACKETRY
TOOL-420 1-C
E4755-F
Backlash Change Required Thickness Change Required Backlash Change Required Thickness Change Required
mm Inches mm Inches mm Inches mm Inches
.025 .001 .050 .002 .228 .009 .304 .012
.050 .002 .050 .002 .254 .010 .355 .014
.076 .003 .101 .004 .279 .011 .355 .014
.101 .004 .152 .006 .304 .012 .406 .016
.127 .005 .152 .006 .330 .013 .457 .018
.152 .006 .203 .008 .355 .014 .457 .018
.178 .007 .254 .010 .381 .015 .508 .020
.203 .008 .254 .010 - - - -

ALL RIGHTS RESERVED
r MORE BACKLASH
LESS BACKLASH + 1 16. Recheck backlash. If backlash is within
specification, proceed to Step 17. If backlash is
not within specification, repeat Step 13.
DECREASE (- )INCREASE (+) DECREASE (-) INCREASE (+ J
FOR MORE FOR LESS FOR LESS FOR MORE Backlash Specification: 0.20-0.38mm
BACKLASH BACKLASH BACKLASH BACKLASH (0.008-0.015 inch) (0.30-0.38mm [0.012-0.015
LEFT SIDE RIGHT SIDE
inch] preferred).
DIAL INDICATOR
WITH BRACKETRY
TOOl-4201-C
14. Install shim and bearing cap. lighten cap bolts to

95-115 N·m (70-85 Ib-ft).
E4755-F
17. Remove bearing caps and bolts. To establish

differential bearing preload, increase both left and
right shim sizes by o. 152mm (0.006 inch) using
Shim Driver T85L-4067-AH. Make sure shims are
fully seated and assembly turns freely.
15. Rotate assembly several times to make sure INCREASE SHIM BY INCREASE SHIM BY
0.152 MM (0.006 IN.) 0.152 MM (0.006 IN.)
differential bearings seat properly.
E8802·B

ALL RIGHTS RESERVED
Axle Shaft Installation

1. Slide ~he a~le shafts (4234) into place in the axle
housing. Use care so that the splines or any
portion of the axle shafts do not damage the oil
seals. Push the ~xle shafts inboard enough to
allow installation of the U-washers.
2. NOTE: A rubber a-ring is used to hold the
U-washer in position on the axle shaft. Be sure
that the a-ring is in the groove at the button end
NOTE: The bottom end of the axle shafts with the
4. 10 ratio F-150 will have splines around the
perimeter matching the long shaft splines. Use
extra care to install that design shaft into the side
gear splines.
Install the U-washers on the button end of the axle
shafts and pull the axle shafts outboard so that
the shaft lock seats in the counterbore of the
SHIM DRIVER
differential side gears.
T85L-4067-AH
E5900-D
O-RING
18. Install bearing caps and tighten bolts to 95-115
N·m (70-85 Ib-ft). Recheck backlash. If not to
specification, repeat Step 12.
19. Utilize white marking compound to obtain a tooth
mesh contact pattern in your assembly. Pattern
legibility can be improved by connecting the
driveshaft (4602) and rotating both tires in drive
and coast direction.
Reincorporation of pattern inspection is intended
to allow technician the ability to detect gross
errors in set-up prior to complete reassembly.
Pattern contact should be within the primary area
of the ring gear tooth surface avoiding any
"narrow" or "hard" contact with outer perimeter
of tooth (top to root, toe to heel). Pattern
inspection should be on the drive (pull) side.
Assembly with correct drive pattern will result in U-WASHER
satisfactory coast performance. If gross pattern 4N237
error is detected, with preferred backlash
E4109-D
(0.30-0.38mm [0.012-0.015 inch]) recheck
pinion shim selection. Refer also to Section 05-00
for typical good and unsatisfactory tooth contact
patterns.

ALL RIGHTS RESERVED
3. Position the differential pinion shaft (4211) Cover Installation

through the differential case and differential pinion 1. CAUTION: Make sure machined surfaces on
gear (4215), aligning the hole in the differential both axle housing cover (4033) and carrier
pinion shaft with the bolt hole. Apply Stud and are clean and free of oil before installing the
Bearing Mount EOAZ-19554-BA or equivalent new silicone sealant. Inside of rear axle
meeting Ford specification WSK-M2G349-A 1 to (4001) must be covered when cleaning the
the lock bolt threads. Install lock bolt and tighten machined surface to prevent contamination.
to 20-40 N·m (15-30 Ib-ft).
Clean the gasket mating surface of the rear axle
carrier casting and axle housing cover.
2. Apply a new continuous bead of Silicone Rubber
D6AZ-19562-AA or -BA or equivalent meeting
Ford specification ESB-M4G92-A or
ESE-M4G 195-A to the new axle housing cover.
LOCK BOLT
4241
DIFFERENTIAL
PINION SHAFT
4211
E4708-e
F8414-A
4. Remove the oil seal replacer from the extension
housing (7A039). Install the driveshaft in the 3. NOTE: Axle housing cover assembly must be
extension housing. Align the scribe marks on the installed within 15 minutes of application of the
rear axle companion flange and driveshaft and silicone or new sealant must be applied. If time
connect the driveshaft at the rear axle companion permits, allow one hour before filling with lubricant
flange. Tighten attaching bolts and nuts to 95-128 to make sure silicone sealant has properly cured.
N·m (70-95 Ib-ft) for rear axle companion flange.
Install axle housing cover and tighten bolts to
38-52 N·m (28-38Ib-ft) as shown. Tighten the
cover bolts in a cross-wise pattern to prevent
axle housing cover from getting cocked.
5. Install the brake drums (1126).

6. Install the wheels and tires. Tighten the wheel E4711-D
lugnuts to 135 N·m (100 Ib-ft). Install the wheel
covers.

ALL RIGHTS RESERVED
4. Add lubricant through the filler hole until the c. Firmly grasp rear brake anti-lock sensor at
lubricant level is 1/ 4 to 9/ 16 inch below the sides (do not install by applying force on
bottom of the filler hole with the axle in the running connector) and push into rear axle housing,
position. All conventional and Traction-Lok® axles aligning mounting flange hole with threaded
except F-150 Lightning and 4. 10: 1 ratio 8.8 inch hole in rear axle housing.
ring gear axles use Motorcraft Synthetic Rear d. Install hold-down bolt and tighten to 34-41
Axle Lubricant, XY-80W90-QL or equivalent N·m (25-30 Ib-ft).
meeting Ford specification WSP-M2C 197-A plus
2 ounces of friction modifier F3TZ-19B546-MA or
WSP-M2C 196-A for complete refill of
Traction-Lok® Rear Axles. F-150 Lightning and
4. 10: 1 ratio axles use synthetic lubricant
F 1TZ-19580-B or equivalent meeting Ford
specification WSL-M2C192-A plus 5 ounces of
Friction Modifier F3TZ-19546-MA or equivalent
meeting Ford specification WSP-M2C 196-A.
Install the filler plug and tighten to 20-40 N·m
(15-30 Ib-ft).
ONBR017 O-RING
VIEW A H6309-D
Sensor, Anti-Lock Brake, Installation
1. If new rear brake anti-lock sensor (2C 190) is to 3. Lower vehicle and road test.
be installed, lightly lubricate O-ring with motor oil.
a. Firmly grasp rear brake anti-lock sensor at
sides (do not install by applying force on CLEANING AND INSPECTION
connector) and push into rear axle housing,
aligning mounting flange hole with threaded Inspection Before Disassembly of Carrier
hole in rear axle housing.
The differential and drive pinion should be inspected
b. Install hold down bolt and tighten to 34-40 before they are removed from the carrier. These
N·m (25-30 Ib-ft). inspections can determine the cause of the concern
2. If old rear brake anti-lock sensor is to be and the resolution.
reinstalled, clean and blow off metal particles 1. Wipe the lubricant from the internal working parts
using compressed air. and visually inspect the parts for wear or
a. Remove and replace O-ring with a new damage.
O-ring. 2. Rotate the gears to see if there is any roughness
b. Apply a light film of motor oil to new O-ring. which would indicate damaged bearings or gears.

ALL RIGHTS RESERVED
3. Check the ring gear teeth for signs of scoring, 5. NOTE: There is a space provided between the
abnormal wear or nicks / chips. anti-lock speed sensor ring and the ring gear for
measuring ring gear backface runout.
Check ring gear backface runout. To check ring
DIAL INDICATOR
WITH BRACKETRY
gear backface runout, mount Dial Indicator with
TOOL-4201-C Bracketry TOOL-4201-C or equivalent on the
carrier so the tip of the dial indicator contacts the
backface of the ring gear. Backface runout
should be no more than 0.101mm (0.004 inch).
6. A contact pattern may not always be an
acceptable guide to check for noise. However, if
the pattern is incorrect, the axle will probably be
noisy. Refer to Section 05-00 for contact pattern
example. Proper gear set assembly must be
checked using the Pinion Depth Gauge
T79P-4020-A set which shows the correct pinion
shim required to make sure an acceptable running
condition is achieved. Refer to Axle Assembly in
this section.
Inspection After Disassembly of Carrier

E4755-F 1. Thoroughly clean all parts. Always use new
solvent when cleaning bearings. Do not spin dry
4. Set up a dial indicator and check ring gear bearings with compressed air.
backlash and ring gear backface runout. 2. Oil the bearings immediately to prevent rusting.
Backlash should be 0.20-0.38mm (0.008-0.015
inch) (0.30-0.38mm [0.012-0.0 15 inch] 3. Inspect the parts for any major damage.
preferred). 4. Clean the inside of the rear axle housing (4010)
before rebuilding. When a scored or chipped gear
set is replaced, the rear axle housing must be
washed thoroughly. Inspection procedures for
individual parts are outlined as follows.
Sensor, Anti-Lock Brake
Inspect the rear brake anti-lock sensor for loose metal
particles and clean if required.
Sensor Ring, Anti-Lock
Examine the Rear Anti-Lock Brake System (RABS)
anti-lock speed sensor ring to see that it is firmly
pressed onto the differential case (4204) and check it
for dented, chipped or missing teeth that could result in
erratic RABS performance. If damage is found,
remove and replace anti-lock speed sensor ring.
Gears
Examine the gear teeth for scoring, excessive wear,
nicks and excessive chipping. Worn, scored and
damaged gears cannot be rebuilt to correct a noisy
condition.
Bearing Cups
Check drive pinion bearing cups for deep scores,
galling, or spalling.lf a 0.038mm (0.0015 inch) feeler
RING GEAR BACKFACE RUNOUT
gauge can be inserted between a drive pinion bearing
REAR ANTI-LOCK BRAKE VEHICLES E7182-D
cup and the bottom of its bore at any point around the
cup, the cup must be reseated.

ALL RIGHTS RESERVED
OS-02G-39 Axle, Integral Carrier, a.a-Inch Ring Gear OS-02G-39
Companion Flange, Rear Axle Differential Case

The end of the rear axle companion flange that Make sure that the hubs where the bearings mount are
contacts the bearing cone as well as the nut smooth. Carefully examine the differential case
counterbore and seal surface must be smooth and free bearing shoulders, which may have been damaged
of nicks. when the bearings were removed. The bearings will
fail if they do not seat firmly against the shoulders.
Cone and Roller Assemblies Check the fit (free rotation) of the differential side
When operated in the differential drive pinion bearing gears (4236) in their counterbores.
cups (4616), bearing rollers must turn without
roughness. Examine the roller ends for step wear. If
inspection reveals either a damaged differential drive
pinion bearing cup or a damaged differential pinion
bearing, both parts should be replaced.
Carrier Housing
Make sure that the differential and pinion bearing
bores are smooth. Remove any nicks or burrs from the
mounting surfaces of the rear axle differential carrier
(4141) housing.
SPECIFICATIONS
CLEARANCE, TOLERANCE AND ADJUSTMENTS CLEARANCE, TOLERANCE AND ADJUSTMENTS

(INTEGRAL CARRIER) (INTEGRAL CARRIER) (Cont'd)
Description Inches Description Inches
Maximum Runout of Back Face of Ring Gear 0.004 Available Pinion Gear Shims in Steps of 0.021-0.037
0.001 Inch
Maximum Runout of Back Face of Differential 0.003
Case Flange Backlash Between Ring Gear and Pinion Teeth 0.008-0.015
(0.012-0.015
Differential Side Gear Thrust Washer 0.030-0.032
Preferred)
Thickness
Maximum Backlash Variation Between Teeth 0.004
Differential Pinion Gear Thrust Washer 0.030-0.032
Thickness Maximum Runout of Companion Flange in 0.012TIR
Assembly
Nominal Pinion Locating Shim 0.030
Sensor Pole to Top of Sensor Ring Gap 0.005-0.045
(Continued)
Axle Shaft Endplay

Axle shaft endplay is allowable up to 0.762mm (0.030
inch), but can be as low as O. 127mm (0.005 inch). It is
controlled by the C-washer that holds the axle shaft in
the pocket of the side gear. To reduce clearance,
replace differential side gears, Traction-Lok@ clutch
plates if equipped, thrust washers or axle shafts as
required.
LUBRICANT CAPACITIES AND CHECKING PROCEDURES (INTEGRAL CARRIER) - CONVENTIONAL
Approximate Lubricant Capacity·
Vehicle Engine Axle U.S. Pints Imperial Pints Liters
b
F-150 All 8.8 Inch Ring Gear 5.50 4.58 2.60
Bronco All 8.8 Inch Ring Gear 5.50 b 4.58 2.60
a All conventional and Traction-Lok@ Axles except F-150 Lightning and 4.10: 1 ratio 8.8 inch ring gear axles use Motorcraft Synthetic Rear
Axle Lubricant, XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A plus 2 ounces of friction modifier
F3TZ-19B546-MA or equivalent meeting Ford specification WSP-M2C196-A for complete refill ofTraction-Lok@ Rear Axles. F-150
Lightning and 4.10: 1 ratio axles use synthetic lubricant F 1TZ-19580-B or equivalent meeting Ford specification WSL-M2C 192-A plus 5
ounces of Friction Modifier F3TZ-19B546-MA or equivalent meeting Ford specification WSP-M2C 196-A.
b Lubricant levels are determined by filling the axle 1/4 to 9/16 inch below the bottom of the filler hole with vehicle in a level position.
NOTE: Rear axle lube quantities must be replaced every 160,000 km (100,000 miles) or if the axle has been submerged
in water. Otherwise, the lube should not be checked or changed unless a leak is suspected or repair required.

ALL RIGHTS RESERVED
TORQUE SPECIFICATIONS (INTEGRAL CARRIER), SPECIAL SERVICE TOOLS REQUIRED (Cont'd)

CONVENTIONAL
Tool Number/
Description N·m Lb-Ft Description illustration
Differential Bearing Cap Bolt 95-115 70-85 T85L-4067-AH
Shim Driver
~
Differential Pinion Shaft Lock Bolt, 20-40 15-30
Using Loctite@ EOAZ-19554-B
(or equivalent)
Ring Gear Attaching Bolts, Using 95-115 70-85 T85L....7-AH
T79P-4020-A
or equivalent
Pinion Depth Gauge
Rear Cover Bolt 38-52 28-38
,~ 7
'l n J
h~~
Rear Axle Housing Vent
Brake Backing Plate Nuts
20-34
28-54
15-25
20-40
81lrkl=~
,~ ~.,~
aD
95-128 ~
~~
Driveshaft to Rear Axle Companion 70-95
Flange Attaching Bolts - Bronco
RABS Sensor Hold-Down Bolt 34-40 25-30
€I
..
T79P-402G-A
ADJUSTMENT TORQUE SPECIFICATIONS T57L-4221-A2

(INTEGRAL CARRIER) - CONVENTIONAL Differential Side Bearing
~
Replacer
Rotational Torque 8
Description N·m Lb-In
T57L-4221-A2
Pinion Bearing Preload -
Collapsible Spacer T70P-4221-A
~
- Used Bearings .9-1.5 8-14 Differential Side Bearing
- New Bearings 1.8-3.3 16-29 Remover
a With pinion seal installed.
T70P-4221-A
SPECIAL SERVICE TOOLS/EQUIPMENT T67P-4616-A


Tool Number /
~ T67P-4616-A
T71 P-4621-B
T50T-100-A
Pinion Bearing Cone Remover
Impact Slide Hammer
T83T-1225-A
~ TSOT·1OG-A U~ ~
T71 P-4621-B
~
Axle Wheel Bearing Puller
T83T-4676-A
Pinion Seal Replacer
T83T-1225-A
Q@
T83T-4678·A
T83T-1175-B
Hub Seal Replacer T77F-4220-B 1
~ ~
Puller-Differential Side Bearing
T83T-1175-8
T77F-4220-B1
T83T-1225-B
@
Axle Bearing Replacer
T83T-1225-8
TOOL·4201·C Dial Indicator with Bracketry
TOOL-4858-E C0"1'anion Range Replacer
(Continued)

ALL RIGHTS RESERVED
05-02H-1 Differential, Traction-Lok, Limited Slip, a.a-Inch Ring Gear 05-02H-1
SECTION 05-02H Differential, Traction-Lok, Limited

Slip, a.a-Inch R~ng Gear·
i
VEHICLE APPLICATION •••••.••.•••••••••••..•.••.••••••••••••••••OS-02H-1 DISASSEMBLY AND ASSEMBLY
DESCRIPTION AND OPERATION Differential Case •••••••.•.•••••••.•..•..••••••••••• ~ •••.••••. OS-02H-3
it •••
Description .•••••••••••.••••••••••••••..••••••••.•..•••••••••.••••••OS-02H-1 ADJUSTMENTS 4
Noise Acceptability •••••.••.•••.•••••••••••••.•••••••••••••••..•OS-02H-3 Bench Torque Test ••••••••••••••••••••••••••••••••••••••••••••••OS-02H-8

Operation •••••••••••••••••••••••••••••.••••••••••••••••••••••••••••••OS-02H-2 Clutch Pack Preload Adju8tment ••••••••••••••••.•.•••••••OS·02H-3
DIAGNOSIS AND TESTING In-Vehicle Adjustments •••••••••••••••••••••••••.••••.•••••••••OS·02H-3
Differential, Tractlon-Lok@ Limited Slip .•..•••••..•.•••OS-02H-3 SPECiFiCATIONS •.••••••••••••••••••••.....•••••••••••••••••••••••••OS·02H-9
REMOVAL AND INSTALLATION SPECIAL SERVICE TOOLS/EQUIPMENT ••••.•••••••••••••OS·02H·9
Differential, Tractlon-Lok@ Limited Slip ••••••••••••••..OS-02H-3
VEHICLE APPLICATION
F-150, F-150 Lightning and Bronco Vehicles Equipped
with B.B-Inch Ring Gear Axle
Description
The limited slip axle assembly is identical to the
conventional rear axle (4001) except for the
differential case (4204).
The limited slip differential (4026) employs two sets of
differential clutch packs (4947) to control differential
action. The mounting distance of the differential side
gear (4236) is controlled by seven plates on each
side: four steel, three friction, and one steel rear axle
differential clutch shim (4A324). This steel rear axle
differential clutch shim is of the selective type to
control the position of the differential 'side gear.
The plates are stacked on the side gear hub and are
housed in the differential case. Also located in the
differential case, between the differential side gears, is
a differential clutch spring (4214), which applies an
initial force to the differential clutch pack. Additional
clutch capacity is delivered from the thrust loads of
the differential side gear. Splined plates are splined to
the side gear hubs which, in turn, are splined to the
axle shaft (4234). The friction plate ears are keyed to
the case so the differential clutch packs are always E9248·A
engaged.
ALL RIGHTS RESERVED
Operation CAUTION: Extended use of other than matching

The pressure between differential clutch packs (4947) size spare tires on a Traction-Lok@ rear axle
opposes differential action at all times. When the (4001) could result in reduction in effectiveness
vehicle turns a corner, the differential clutch pack (bias torque). This loss of effectiveness does not
slips, allowing normal differential action to take place. affect normal driving and should not be
Under adverse weather conditions, where one or both noticeable to the driver. However, extended
wheels may be on a low-traction surface such as usage will reduce the ability of the rear axle to
snow, ice or mud, the friction between the clutch provide added traction on slippery surfaces.
plates will transfer a portion of the usable torque to the
wheel with the most traction. Thus, the wheel that is
on ice or snow will have a tendency to· operate with the
opposite wheel in a combined driving effort.
Differentia~ Case Components
E6076-G
Part Part
1 4211 Differential Pinion Shaft 5 4A324 Rear Axle Differential Clutch
2 4230 Differential Pinion Thrust Shim
Washer 6 4947 Differential Clutch Pack
3 4241 Differential Pinion Shaft Lock 7 4215 Differential Pinion Gear
Pin 8 4214 Differential Clutch Spring
4 4204 Differential Case 9 4236 Differential Side Gear
(Continued)
ALL RIGHTS RESERVED
DESCRIPTION AND OPERATION (Continued) ADJUSTMENTS
Noise Acceptability In-Vehicle Adjustments

A gear-driven unit (especially on a drive axle) will NOTE: Refer to Section 05-02G for rear brake
produce a certain amount of noise. Some noise is anti-lock sensor service on anti-lock brake
acceptable and may be audible at certain speeds or system-equipped vehicles.
under various driving conditions, as on a newly paved
In-vehicle adjustments are possible on this unit without
blacktop road. The slight noise is in no way detrimental
removing the differential case (4204) from the axle
to operation of the rear axle (4001) and must be
housing. If the operation check was not to
considered normal.
specification, use the following procedure to correct
Vehicles equipped with a limited slip Traction-Lok@ the condition.
differential may exhibit a slight stick-slip noise
(chatter) on tight turns after extended highway driving.
This is considered acceptable and has no detrimental
effect. Clutch Pack Preload Adjustment
Gear Rotator T80P-4205-A
Differential, Traction-Lok® Limited Slip
Traction-Lok~ Clutch Gauge T87T-4946-A
1. NOTE: Before preload can be adjusted, the axle
shafts (4234) must be removed following the
REMOVAL AND INSTALLATION procedure in Section 05-02G. The axle $hafts
must be removed completely from the axle
housing so that the oil seals will not be damaged.
Differential, Traction-Lok® Limited Slip After preload adjustment, install the axle shaft
Removal and installation procedures for the limited slip following the procedure in Section 0~-02G.
differential axle shaft (4234), inner wheel bearing oil WARNING: DUE TO THE SPRING TENSION,
seal (1177), rear wheel bearing (1225), rear axle CARE MUST BE USED WHEN 'REMOVING THE
housing (4010) and pinion seal are the same as those DIFFERENTIAL CLUTCH SPRING (4214).
for the Ford truck 8.8-inch ring gear integral carrier
axle with a conventional differential. Refer to Section With a suitable drift, drive the differential clutch
05-02G for these procedures. spring half-way out of the differential case
(4204). Rotate the differential case 180 degrees.
Hold the differential clutch spring with a pair of
pliers and tap the differential clutch spring until it
DISASSEMBLY AND ASSEMBLY is removed from the differential case.
Differential Case REAR AXLE

DIFFERENTIAL CLUTCH
To disassemble and assemble the differential case SPRING
(4204), remove and install the ring gear and pinion and 4214
the differential pinion bearing (4621) assemblies.
Refer to Section 05-02G.
NOTE: It is not necessary to remove the differential
bearings (4221) from the differential case unless they
are damaged. If the differential bearings remain on the
differential case during repair, keep th~m cleall and
free from foreign material.
To remove and' install the differential clutch spring
(4214), differential pinion shaft (4211), differential
side gears (4236) and differential clutch packs
(4947), refer to Adjustments in this section.
E9249·A
ALL RIGHTS RESERVED
2. NOTE: A 304.8mm (12 inch) extension is RIGHT SIDE

required to remove the differential pinion gears GEAR-4236 AND
(4215). DIFFERENTIAL CLUTCH
___- - - _ PACK-4947
Using Gear Rotator T80P-4205-A rotate the
pinion gears until they can be removed from the
differential case.
GEAR ROTATOR
TSOP-4205-A
3. NOTE: Do not mix differential clutch packs

(4947) or rear axle differential clutch shims
(4A324) from one side with the other.
Remove the right and left differential side gears
(4236) and differential clutch pack with the shim
and tag them Uright" and uleft." Set them aside.
Clean and inspect the remaining parts of the
differential case assembly for wear or damage.
Replace parts as required. E9261·A
4. NOTE: Do not use acids or solvents when
cleaning differential clutch pack. Wipe
components with a clean, lint-free cloth only.
Clean and inspect the differential clutch packs for
wear and replace parts as necessary.
REAR AXLE
DIFFERENTIAL CLUTCH
SHIM
4A324
E608&-C

ALL RIGHTS RESERVED
5. CAUTION: Prelubricate all friction clutch

plates with Additive Friction Modifier DIFFERENTIAL
F3TZ-19B546-MA or equivalent meeting CLUTCH PACK-4947
Ford specification WSP-M2C196-A by AND SIDE GEAR
4238
soaking the plates for 15 minutes.
NOTE: Do not mix differential clutch packs or
rear axle differential clutch shims from one side
with the other.
Assemble the differential clutch packs (without
rear axle differential clutch shims) on the
respective differential side gears.
DIFFERENTIAL
CLUTCH PACK
4947
E&723·D
7. Install the disc of the gauge over the base and on

top of the differential clutch pack.
6. Place the base portion of Traction-Lok@ Clutch

Gauge T87T-4946-A in a vise. Install the
differential clutch pack and differential side gear
(without the rear axle differential clutch shim)
over the base.
DISC-TRACTION-LOK
CLUTCH GAUGE
T80P-4946-A
E5724-B
1995 F-150, F-250, F·350, Bronco, F-Super Duty Powertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
05-02H-6 Differential, Tractlon-Lok, Limited Slip, a.a-Inch Ring Gear 05-02H-6
8. Install the top portion of the gauge over the disc 10. Using Feeler Gauge D81L-4201-A or equivalent,
and base stud. select the thickest blade that will enter between
the tool and the differential clutch pack. This
reading will be the thickness of the new rear axle
TOP-TRACTION-lOK differential clutch shim.
CLUTCH GAUGE
T80P-4946-A
TRACTION-LOK
CLUTCH GAUGE
T80P-4946-A
E5082-D
E5725·B
9. Install the nut of the gauge over the top and base
stud. lighten the nut to 6.7 N·m (60 Ib-in).

ALL RIGHTS RESERVED
05-02H-7 Differential, Traction-Lok, Limited Slip, S.S-Inch Ring Gear 05-02H-7
11. NOTE: Be sure to lubricate friction clutch plates

with Additive Friction Modifier F3TZ-19B546-MA
WSP-M2C 196-A prior to reassembly.
Install the differential side gear, differential clutch
pack and new rear axle differential clutch shim
into the cavity in the differential case. Repeat
these procedures for the other side.
RIGHT SIDE
GEAR-4238 AND
DIFFERENTIAL CLUTCH
_ _- - -_ _ PACK-4947
E9262-A
13. Rotate the tool until the differential pinion gears

are aligned with the pinion shaft hole as shown.
Remove the tool from the differential case.
GEAR ROTATOR
T80P-4205-A
LEFT SIDE
GEAR-4236 AND
DIFFERENTIAL
CLUTCH PACK-4947
E9251·A
12. NOTE: A 304.8mm(12 inch) extension is

required to install the differential pinion gears.
Place the differential pinion gears and differential
pinion thrust washers (4230) 180 degrees apart
on the differential side gears. Install Gear Rotator
T80P-4205-A as shown.

ALL RIGHTS RESERVED
05-02H-8 Differential, Traction-Lok, Limited Slip, 8.8-lnch Ring Gear 05-02H-8
14. NOTE: Inspect the differential clutch spring for With the locker tools in T66L-4204-A, check the
damage. torque required to rotate one differential side gear
Hold the differential clutch spring up to the (4236) while the other is held stationary.
differential case window and, with a soft-faced The initial break-away torque, if original clutch plates
hammer, hammer the differential clutch spring into are used, should be at least 27 N·m (20 Ib-ft). The
position. rotating torque required to keep the differential side
gear turning with new clutch plates may fluctuate.
TORQUE WRENCH
OF AT LEAST 271 N·m
(200 LB-FT) CAPACITY
TRACTION-LOK
TORQUE TOOL
T86L-4204-A
Bench Torque Test

Traction-Lok~ Torque Tool T66L-4204-A
E9230-B
A bench torque test must be made if the differential
case (4204) has been removed from the rear axle
housing (4010) and adjustments have been made.

ALL RIGHTS RESERVED
SPECIFICATIONS
LUBRICANT CAPACITIES AND CHECKING PROCEDURES (INTEGRAL CARRIER) - LIMITED SLIP

u.s. Measure Imperial Capacity
Vehicle Engine Axle Capacity (Pints) ab (Plnts)ab Lltersab
F-150,Bronco(4x4) All 8.8-lnch Ring Gear 5.5 4.6 2.6
a For F-150, Bronco other than 4. 10 ratio, use Rear Axle Lubricant XV-80W90-QL or equivalent meeting Ford specification
WSP-M2C 197-A, plus 2 U.S. ounces of Additive Friction Modifier. For Traction-Lok~ rear axles other than 4. 10 ratio use
F3TZ-19B546-MA or equivalent meeting Ford specification WSP-M2C 196-A.
b For F-150 Lightning, F-150 and Bronco with 4.10:1 ratio use 2.61 (5.5 pints) synthetic rear axle lubricant, F1TZ-19580-B,
(WSL-M2C192-A). For F-150 Lightning with Traction-Lok~, add 148 ml (5 ounces) of F3TZ-19B546-MA (M2C196-A) Friction Modifier.
Bronco 4.10 ratio requires 148 ml (5 ounces).
NOTE: Synthetic lubricants have no equivalents. Use no other lubricant.
BACKLASH BETWEEN RING GEAR AND PINION SPECIAL SERVICE TOOLS REQUIRED (Cont'd)
Description mm Inch Tool Number I
Description IIluJtratlon
Backlash 0.20-0.38 0.008-0.015
T87T-4946-A
~
Ring Gear Backface Runout 0.10 0.004
Traction-Lok~ Clutch Gauge
TORQUE SPECIFICATIONS Tin-4I41-A

(INTEGRAL CARRIER), LIMITED SLIP
T66L-4204-A
Description N·m Lb-Ft Traction-Lok~ Torque Tool
Axle Housing Cover Screw
Oil Filler Plug
34-47
20-40
25-35
15-30 ~ T88L-42CM-A
ADJUSTMENT TORQUE SPECIFICATIONS

(INTEGRAL CARRIER), LIMITED SLIP SPECIAL SERVICE TOOLS DESIRED
Description N·m Lb-Ft Tool Number Description
Minimum Rotating Torques Required 27 20 D81L-4201-A Feeler Gauge
During Bench Check after Assembly
or in Vehicle with One Wheel on the
Ground for Original Clutch Pack.

Tool Number I
T80P-4205-A
Gear Rotator
~ TIOP-4205-A
T80P-4946-A
Traction-Lok~ Clutch Gauge
fb T80P-4.....A
(Continued)
ALL RIGHTS RESERVED
05-03A-1 Axle, Front Drive, Dana Models 44 and 50 05-03A-1
SECTION 05·03A Axle, Front Drive, Dana Models 44

and 50
VEHICLE APPLICATION .••••••••••••.••..•..••....•...•.•.••••••••05-03A-1 DISASSEMBLY AND ASSEMBLY
DESCRIPTION AND OPERATION .•••••.•••.•••••.........•....05-03A-1 Bearing Cup and Drive Pinion
DIAGNOSIS AND TESTING Installation .••..•.•....•.•••...•.•....•.•.....•............•....05-03A-31
Axle, Front Drive•••••••••••••••.••.•..•••..•••.....•..••...••.••.•05-03A-7 Cardan-Type U-Joints .••.•..••..••..•••.•••..•••...••...•.•••05-03A-25
REMOVAL AND INSTALLATION Carrier•••.•.•.....••........••....•....••....•...•••....••...••...•.•05-03A-25
Axle Housing Pivot Bushing (IFS Front Drive Depth Gauge Check•.••••..••...••.••..••..••.•..•.....•.•....05-03A-30
Axle) .••••••••••••••••••••••••.••..••.•.••.••.•••.••...••.••••••.••05-03A-25 Differential Case •...•....•...••...•...••.••.••..•..••••••..••..05-03A-32
Dana Four-Wheel Drive Front Axle, F-150 4x4 Differential Case Assembly to Carrier ....•...•....••.05-03A-33
and Bronco with Coli Sprlngs •••..•••••.••••••••••••••••.05-03A-8 Pinion and Ring Gear Backlash .•..••...•....•........05-03A-33
Dana Four-Wheel Drive Front Axle, F-250 4x4 Drive Pinion Installation ...••...•...••.••..•..••••..•••••••••05-03A-28
with Leaf Spring Front Suspension •••..••..••••....05-03A-11 Drive Pinion Preload Check••..•......••........•......•...05-03A-32
Differential Seal, LH ••••••••••••..•...•••...•..••.•..•••••.••.•05-03A-24 Gear Tooth Contact Pattern Check .. ~ •..••.•...••..•••05-03A-35
Slip-Yoke, RH, and Stub Shaft Assembly, Total Differential Case End Play ••••.•.•••••••..•••••••••05-03A-27
Carrier, Carrier 011 Seal and Bearing •••••...•••..•.05-03A-21 SPECIFICATIONS ••••..•••.•••....••....•...•.....•..........••..••05-03A-38
Spindle, RH and LH Shaft and Joint SPECIAL SERVICE TOOLS/EQUIPMENT ••.....•....•...05-03A-38
Assembly •••••••••••••••••••••••••••••••••.••••••••..••••••••.••05-03A-16
Steering Knuckle ••.•••.••••.•••••••••••••••••••.••••..•.....•..05-03A-13
VEHICLE APPLICATION
F-150, F-250 4x4 and Bronco
Three types of Dana front-drive axles are available for The 44-IFS, the 44-IFS-HD and the 50 IFS may be
Ford light truck application. The Dana 44-IFS equipped with either automatic hubs or manual locking
(Independent Front Suspension) is available on Bronco hubs. .
and F-150 4x4. The Dana 44-IFS-HD (Independent The front axle is of the integral carrier-housing, hypoid
Front Suspension - Heavy-Duty) is available on gear type, in which the centerline of the drivs pinion is
F-250 4x4. The Dana 50-IFS (Independent Front mounted above the centerline of the ring gear.
Suspension) is available on F-250 4x4 equipped with
Heavy-Duty Front End option or F-250 SliperCab On IFS front driving axles, the cover on the front of the
vehicles. carrier housing is integral with the left axle arm
assembly. A metal tag, stamped with the gear ratio
All axles are basically alike with some differences and part number, is secured to the housing by one of
between the three. The 44-IFS is on vehicles equipped the carrier mounting bolts (Section 05-00).
with front coil springs. The 44-IFS-HD and 50-IFS are
on vehicles equipped with front leaf springs.
1995 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain July 1994 l

ALL RIGHTS RESERVED
05-03A-2 Axle, Front Drive, Dana Models 44 and 50 05-03A·2
Dana 44-IFS Front Drive Axle, Bronco and F·150 4x4 with Automatic Hub Locks
1995 F~ 150, F~250, F~350, Bronco, F~Super Duty Powertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
Part Part
1 3219 Shaft (RH) 42 4616 Differential Drive Pinion
2 3B402 Axle Arm Assembly Bearing Cup
3 3B177 Pivot Bushing 43 4109 Drive Pinion Shim (Preload)
4 3010 Housing 44 3B403 Weld Nut
5 - RTV Gasket (Form in Place) 45 1175 Rolling Diaphragm Seal
6 4222 Differential Bearing Cup 46 72035-S Pin
7 3L387 Slip Shaft 47 3A049 Nut
8 4A460 Seal 48 3049 and 3050 Front Suspension Upper and
Lower Ball Joint
9 802857 Keystone Clamp
49 87747-S2 Filler Plug
10 3A429 Boot
50 2K004 Front Disc Brake Rotor
11 3249 Front Axle Shaft Universal Shield (RH)
Joint
12 3M387 Shaft Shield (LH)
13 3254 Oil Seal 52 3299 Integral Spacer / Seal
14 3L123/1225 Bearing 53 3123 Bearing, Caged Needle
15 3167 C·Clip 54 3105 Front Wheel Spindle
16 3204 Case Assembly 55 3254 Spindle Rolling Diaphragm
17 350672·S Bolt Seal (RDS)
18 4211 Differential Pinion Shaft 56 1190 Wheel Bearing Seal
19 4230 Differential Pinion Thrust 57 4221 Inner Wheel Bearing Cone
Washer 58 4222 Inner Wheel Bearing Cup
20 4228 Differential Side Gear Thrust 1102 Rotor
59
Washer
60 1102 Hub
61 35704 Nut
22 4215 Pinion Gear
62 4222 Outer Wheel Bearing Cup
23 - Cap, Differential Bearing
63 4221 Outer Wheel Bearing Cone
(Part of 3010)
24 4221 Differential Bearing 64 - Wheel Retainer (Nut)
(Part of 1K 105)
65 3B549 Wheel Retainer Key
26 3254 Axle Shaft Oil Seal
27 4670 Baffle
66 - C-Assembly (Part of 1K 105)
28 4672 Shim
67 - Steel Thrust Washer
(Part of 3B458)
29 4628 Rear Axle Pinion Bearing
Cup
68 - Plastic Thrust Washer
(Part of 3B458)
69 - Splined Thrust Washer
31 3B067 Selective Shim Slinger (Part of 3B458)
32 3222 Ring Gear and Drive Pinion 70 3B457 C-Ring
33 3B404 Camber Adjuster 71 1K105 Hub Body
34 357228·S RoUPin 72 1K014 Lockring
35 4851 Rear Axle Companion Flange 73 1K104 Cap
36 351126..S Nut 74 1Kl04 Capscrew
37 356504..S Washer 75 33925-S Jam Nut
38 4859 Drive Pinion Seal Deflector 76 3130 Steering Knuckle (RH)
39 4676 Pinion Seal 77 3131 Steering Knuckle (LH)
40 4670 Oil Slinger 78 373912-S Stop Screw
41 4621 Differential Pinion Bearing 79 3K050 Snap Ring
(Continued) 80 3A050 Nut
1995 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain-July 1994

ALL RIGHTS RESERVED
OS-03A-4 Axle, Front Drive, Dana Models 44 and SO OS-03A-4
_ Dana 44-IFS Front Drive Axle, Bronco and F-150 4x4 with Manual Hub Locks
ALL RIGHTS RESERVED
05-03A-5 Axle, Front Drive, Dana Models 44 and 50 OS-03A-S
Part Part
1 3219 Shaft (RH) 42 4616 Differential Drive Pinion
2 3B402 Axle Arm Assembly Bearing Cup
3 3B177 Pivot Bushing 43 4109 Drive Pinion Shim (Preload)
4 3010 Housing 44 3B403 Weld Nut
6 4222 Differential Bearing Cup 46 72035-S Pin
7 31387 Slip Shaft 47 3A049 Nut
8 4A460 Seal 48 3049 and 3050 Front Suspension Upper and
Lower Ball Joint
9 802857 Keystone Clamp
10 3A429 Boot
Joint
13 3254 Oil Seal 52 3299 Integral Spacer / Seal
14 3l123/1225 Bearing 53 3123 Bearing, Caged Needle
15 3167 C-Clip 54 3105 Front Wheel Spindle
16 3204 Case Assembly 55 3254 Spindle Rolling Diaphragm
17 350672-S Bolt Seal (RDS)
18 4211 Differential Pinion Shaft 56 1190 Wheel Bearing Seal
Washer 58 4222 Inner Wheel Bearing Cup
20 4228 Differential Side Gear Thrust 59 1102 Rotor
Washer
60 1102 Hub
61 35704 Nut
22 4215 Pinion Gear
62 1198 Lockwasher
23 - Cap, Differential Bearing
63 1197 Outer locknut
(Part of 3010)
24 4221 Differential Bearing 64 4222 Outer Wheel Bearing Cup
25 4067 Differential Bearing Shim 65 4221 Outer Wheel Bearing Cone
26 3254 Axle Shaft Oil Seal 66 1195 Inner Locknut
27 4670 Baffle 67 - Steel Thrust Washer
(Part of 3B457)
28 4672 Shim
29 4628 Rear Axle Pinion Bearing
(Part of 3B457)
Cup
(Part of 3B457)
31 3B067 Selective Shim Slinger 70 3B457 C-Ring
32 3222 Ring Gear and Drive Pinion 71 1K105 Hub Body
33 3B404 Camber Adjuster 72 1K104 Lockring
34 357228-S Roll Pin 1K104 Cap
73
35 4851 Rear Axle Companion Flange 74 1K104 Capscrew
36 351126-S Nut 75 33925-8 Jam Nut
37 356504-S Washer 76 3130 Steering Knuckle (RH)
38 4859 Drive Pinion Seal Deflector 77 3131 Steering Knuckle (LH)
39 4676 Pinion Seal 78 373912-S Stop Screw
40 4670 Oil Slinger
79 3K050 Snap Ring
80 3A050 Nut
(Continued)
ALL RIGHTS RESERVED
DESCRIPTION AND OPERA~ION (Continued)
Dana 50-IFS Front Drive Axle, F-250 HD 4x4 with Automatic Locking Hubs
E4101-K
ALL RIGHTS RESERVED
05·03A·7 Axle, Front Drive, Dana Models 44 and 50 05·03A·7
Part Part
1 3219 Shaft (RH) 41 4621 Differential Pinion Bearing
2 3B402 Axle Arm Assembly (RH) 42 4616 Differential Drive Pinion
3 3B177 Pivot Bushing Bearing Cup
4 3010 Housing 43 4109 Drive Pinion Shim (Preload)
6 4222 Differential Bearing Cup 45 3A049 Nut
7 31387 Slip Shaft 46 72035-S Pin
8 4A460 Seal 47 3049/3050 Front Suspension Upper and
Lower Ball Joint
9 802857 Keystone Clamp (2)
10 3A429 Boot
Joint
13 3254 Oil Seal 51 3299 Integral Spacer 1Seal
14 3C123/1225 Bearing 52 3123 Caged Needle Bearing
15 3167 C-Clip 53 3105 Front Wheel Spindle
16 357228-S RoUPin 54 1190 Wheel Bearing Seal
17 3204 Case Assembly 55 1102 Hub and Rotor
18 350672-S Bolt 56 - Hub (Part of 1102)
19 4211 Differential Pinion Shaft 57 4222 Inner Wheel Bearing Cup
Washer
59 35704 Nut
21 4228 Differential Side Gear Thrust
Washer 60 4222 Outer Wheel Bearing Cup
22 4236 Differential Side Gear 61 4221 Outer Wheel Bearing Cone
23 - Cap, Differential Bearing 62 - Wheel Retainer (Nut)
(Part of 3010) (Part of 1K 105)
24 4215 Pinion Gear 63 3B549 Wheel Retainer Key
25 4221 Differential Bearing 64 - Steel Thrust Washer
(Part of 3B458)
27 3254 Axle Shaft Oil Seal
(Part of 38458)
28 4670 Oil Slinger lKl04 Lockring
66
29 4672 Shim 67 lKl04 Capscrew
30 4628 Rear Axle Pinion Bearing 1Kl04
68 Cap
Cup
69 1K105 Hub Body
70 3B457 Snap Ring
32 3B067 Selective Shim Slinger
33 3222 Ring Gear and Drive Pinion
(Part of 3B458)
34 3B404 Camber Adjuster
35 4851 Rear Axle Companion Flange
72 - Cam Assembly
(Part of 1KO 15)
36 351126-S Nut 73 33925-S Jam Nut
37 356504-S Washer 74 373912-8 Stop Screw
38 4859 Drive Pinion Oil Seal 75 3130 Steering Knuckle (RH)
Deflector 3131 Steering Knuckle (lH)
39 4676 Rear Axle Drive Pinion Seal 76 3K050 Snap Ring
40 4670 Rear Axle Drive Pinion Shaft 77 3A050 Nut
Oil Slinger
(Continued)
Axle, Front Drive

ALL RIGHTS RESERVED
Dana Four-Wheel Drive Front Axle, F-150 6. Remove front stabilizer bar (5482). Refer to
4x4 and Bronco with Coil Springs Section 04-01B in the Body, Chassis Manual.
7. Position jack under axle arm assembly and
SPECIAL SERVICE TOOL(S) REQUIRED remove the upper coil spring retainers. Remove
spring lower retainer bolt. Lower the jack and
Description Tool Number remove the front coil spring (5310), spring
Keystone Clamp Pliers T63P-9171-A cushion and lower spring seat.
8. Disconnect the front shock absorber (18124) at
Removal the radius arm and upper mounting bracket.
1. Raise the vehicle on a hoist or jack and install 9. Remove the stud and spring seat at radius arm
safety stands under the radius arm brackets. and axle arm. Remove bolt securing upper
2. Remove the wheel and tire assembly and brake attachment to axle arm radius arm to lower
caliper. Refer to Section 04-04. attachment axle arm.
3. On vehicles equipped with four-wheel anti-lock 10. Disconnect the vent tube at the differential
brakes, remove the front brake anti-lock sensor housing and discard the hose clamps. Remove
(2C204) from the knuckle. Refer to Section the vent fitting and install a 1/8-inch pipe plug.
06-09B in the Body, Chassis Manual. 11. Remove the pivot bolt securing the right axle arm
4. Disconnect the steering linkage from the steering assembly to front crossmember (5019).
knuckles. Refer to Section 11-03 in the Body,
Chassis Manual.
5. Remove front driveshaft (4602). Refer to Section
05-01.

ALL RIGHTS RESERVED
Front Suspension, F-150 and Bronco 4x4
13
15
),.
':t
FRONT OF
VEHICLE
'~
~.
~-@
VIEW A
~
FRONT OF
VEHICLE
-
FRONT OF
VEHICLE
VIEWC VIEW 0
E9240-B

ALL RIGHTS RESERVED
05-03A-10 Axle, Front Drive, Dana Models 44 and 50 05-03A-1(
Part Part
1 N806246-S56 Nut and Washer 33 N805033-S2 Bolt
2 18198 Shock Absorber Bushing 34 18045 Front Shock Absorber
Repair Kit 35 N806085-S8 Nut and Washer
3 5B315 Front Spring Seat Upper 36 380288-S2 Screw and Washer
(LH) Assembly
4 N802210-S Bolt 37 N647096-S Rivet
5 N647096-S Rivet 38 N803500-S2 Screw
6 3B183 Radius Arm Bracket (LH) 39 58654-52 Bolt
7 N800937-S2 Nut 40 34988-S2 Nut
8 379572-S2 Washer 41 3020 Front Suspension Bumper
9 34992-S2 Nut 42 65095-5 Rivet
10 3B463 Radius Arm Heat Shield 43 N801079-S2 Bolt
11 3A184 Outer Radius Arm 44 N620604-S 100 Nut
12 3B244 Spacer 45 N806727-S2 Plate
13 3B203 Front Radius Arm Insulator 46 N801670-S36 Nut
14 3B186 Front Radius Arm Return A - Tighten to 34-46 N·m
15 3405 Radius Arm (25-34 Lb-Ft)
16 N605920-S2 Bolt B - Tighten to 113-153 N·m
17 58740-S100 Screw (83-113 Lb-Ft)
18 3002 Front Axle C - Tighten to 26-34 N·m
(19-25 Lb-Ft)
19 18A151 Shock Absorber Lower
Bracket (RH) 0 - Tighten to 325-351 N·m
(240-259 Lb-Ft)
20 40954-S100 Screw
21 3B446 Axle Radius Arm Bracket
(70-100 Lb-Ft)
22 390678-S 100 Bolt F - Tighten to 60-80 N·m
23 5A307 Lower Spring Seat with (44-59 Lb-Ft)
Stabilizer Bar (RH)
24 5A307 Lower Spring Seat Without
G - Tighten to 35-45 N·m
(26-33 Lb-Ft)
Stabilizer Bar (RH)
25 5A349 Lower Spring Return
H - Tighten to 53-72 N·m
(39-53 Lb-Ft)
26 388833-S2 Nut J - Tighten to 213-288 N·m
27 5A333 Upper Spring Return (157-212 Lb-Ft)
28 40949-S2 Screw K - Tighten to 434-461 N·m
29 5414 Front Spring Insulator (320-340 Lb-Ft)
30 N806496-S 100 Nut and Washer L - Tighten to 76-104 N·m
(56-77 Lb-Ft)
31 N620482-S36 Nut
32 18126 Front Shock Absorber Lower
Bracket
(Continued)
12. Remove and discard the keystone clamps and 2. Using a jack, position the right axle assembly at
remove the boot from the shaft. the front crossmember and radius arm. Install the
13. Remove the right drive axle assembly and pull the boot on the shaft so the boot seats in the
axle shaft from the slip shaft. grooves.
14. Position a jack under the differential housing. 3. Position new keystone clamps over the grooves
Remove the bolt securing the left axle assembly on the boot and crimp the clamp with Keystone
Clamp Pliers T63P-9171-A.
to the front crossmember.
15. Remove the left-hand drive axle. 4. Align the axle shaft and install in slip shaft. Secure
axle assembly to front crossmember with pivot
Installation bolt. lighten to 154-201 N·m (114-148Ib-ft).
1. Raise the vehicle on a hoist or a jack. Position the
left drive axle assembly on a jack and position to
the radius arm. Secure the drive axle to front
crossmember with the pivot bolt. lighten bolt to
163-203 N·m (120-150 Ib-ft).

ALL RIGHTS RESERVED
5. NOTE: Make sure shipping plug has been Removal

removed from vent tube. A plugged vent tube can 1. NOTE: When raising the vehicle on a hoist, make
cause leakage past seals or sealant materials. sure that the hoist lift points do not rest on the
Install vent fitting in differential housing. Connect caliper pins.
vent tube to vent fitting using new hose clamps. Raise vehicle on a hoist or jack and install safety
Route vent hose through hole in crossmember stands.
and clip to the frame side rail.
2. CAUTION: Do not let the disc brake caliper
6. Position spring seat and install a new stud at axle (28120) hang with its weight on the brake
arm and upper radius arm. hose or the hose may become stretched or .
7. Install new bolt at axle assembly and lower radius twisted.
arm. Tighten bolts to 434-461 N·m (320-340 Remove the wheels (1007) and tires, and disc
Ib-ft). brake calipers. Refer to Section 06-03 in the
8. Position front spring insulator (5414) and front Body, Chassis Manual.
coil spring on lower spring seat. Install nut and 3. Disconnect the steering linkage from the steering
tighten to 95-135 N·m (70-100 Ib-ft). knuckles. Refer to Section 11-03 in the Body,
9. Position jack under axle assembly and raise front Chassis Manual.
coil spring into position. Install upper spring 4. Remove front stabilizer bar (5482). Refer to
retainer and screw. Tighten to 17-23 N·m (13-17 Section 04-01B in the Body, Chassis Manual.
Ib-ft).
5. Remove front driveshaft (4602). Refer to Section
10. Lower the jack. 05-01.
11. Connect rear shock absorber service kits 6. Position jack under right-hand axle assembly.
(18045) to upper and lower frame brackets. Remove the two U-bolts securing the shock
12. On vehicles equipped with four-wheel anti-lock absorber mounting plate and front spring to axle
brakes, install the front brake anti-lock sensor on arm.
the knuckle. Refer to Section 06-09B in the 80dy, 7. Disconnect the vent tube at the differential
Chassis Manual. housing. Remove the vent fitting and install a
13. Install disc brake caliper (28120), wheel (1007) 1/8-inch pipe plug or a vacuum fitting cap.
and tire. 8. Remove and discard the keystone clamps and
14. Connect the steering linkage. Refer to Section remove the boot from the shaft.
11-03 in the Body, Chassis Manual. 9. Remove the pivot bolt that secures the right-hand
15. Install the front crossmember. Refer to Section axle assembly to front crossmember (5019).
04-01B in the Body, Chassis Manual. 10. Remove the right axle assembly. Pull the axle
16. Install the front driveshaft. Refer to Section shaft out of the slip shaft.
05-01. 11. Position the jack under the left-hand axle
17. Lower the vehicle. Check and adjust camber and assembly. Remove the two U-bolts securing the
toe. Refer to Section 04-00 in the Body, Chassis shock absorber mounting plate and front spring to
Manual. tube and yoke assembly.
12. Position a jack under the differential housing.
13. Remove the pivot bolt securing the left-hand axle
assembly to front crossmember. Remove the left
Dana Four-Wheel Drive Front Axle, F·250 axle assembly.
4x4 with Leaf Spring Front Suspension
1995 F-150. F-250. F-350. Bronco, F-Super Duty Powertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
F-250 4x4, Leaf Spring Front Suspension
FRONT OF VEHICLE
~
MAIN VIEW
LH SIDE SHOWN, RH SIDE SAME

VIEW A VIEWS
~~--
y::~ ._~ _ 35
:J;.,,"" -~ -
@-~.~-~~~~
CD-... w
VIEW 0
I29
37
®
F2857-L
ALL RIGHTS RESERVED
Part Part
Item Number Description 'Item Number Description
1 3590 Steering Gear Sector Shaft 27 N601522-S2 Bolt
Arm 28 N620485-S56 Nut
2 800895-S56 Nut 29 N620484-S56 Nut
3 N620483-S2 Cotter Pin 30 5L302 Spring Insulator Sleeve
4 5310 Front Leaf Spring 31 5K316 Front Spring Front Shackle
5 N800021-S2 Bolt 32 N800991-S2 Bolt
6 N806496-S30 1 Nut 33 58634-S2 Bolt
7 18183 Front Shock Absorber 34 44877-S2 Washer
Mounting Bracket 35 5340 Front Spring Mounting
8 N802114-S2 Bolt Bracket
9 18045 Rear Shock Absorber 36 N647097-S Rivet
Service Kit 37 34987-S2 Nut
10 5458 Front Spring Plate Spacer A - Tighten to 77 -103 N·m
11 5A500 U-Bolt Spacer (57 -80 Lb-Ft)
12 801342-S2 Nut B - Tighten to 60-80 N·m
13 N805073-S56 U-Bolt (44-59 Lb-Ft)
14 4730 Rear Axle Bumper C - Tighten to 113-153 N·m
15 N620483-S2 Nut (83-113 Lb-Ft)
16 3B251 Rear Axle Bumper Bracket 0 - Tighten to 68-92 N·m
(50-69 Lb-Ft)
17 N620482-S2 Nut
18 N605933-S2 Bolt
(110-148 Lb-Ft)
19 N802114-S2 Bolt F - Tighten to 47-82 N·m
20 N802073-S2 Nut (35-60 Lb-Ft)
21 3B178 Front Suspension Lower Arm G - Tighten to 170-230 N·m
22 N801079-S2 Bolt (125-170 Lb-Ft)
23 N808528-S 100 Bolt and Retainer H - Tighten to 88-118 N·m
24 N620604-S 100 Nut (65-87 Lb-Ft)
25 3K090 Front Axle Bearing Bracket J - Tighten to 30-40 N·m
(22-30 Lb-Ft)
26 N802073-S2 Nut
(Continued)
Installation 6. Install vent fitting to differential housing and

1. Raise vehicle on a hoist or a jack and position left connect vent tube to vent using a new hose
axle assembly at front leaf spring. Install the pivot clamp.
bolt that secures the axle assembly to the front 7. Connect the steering linkage. Refer to Section
crossmember. 11-03 in the Body, Chassis Manual.
2. Secure the shock absorber mounting plate to the 8. Install disc brake caliper and wheel and tire. Refer
front leaf spring and axle assembly with the two to Section 06-03 in the Body, Chassis Manual.
U-bolts. Tighten bolts to 113-153 N·m (83-113 9. Install front driveshaft. Refer to Section 05-0 1.
Ib-ft).
10. Install front stabilizer bar. Refer to Section
3. Position new keystone clamps over the grooves 04-01B in the Body, Chassis Manual.
on the boot and crimp the clamp with Keystone
Clamp Pliers T63P-9171-A. 11. Check and adjust caster, camber and toe.
4. Align the axle shaft and install in slip shaft.
Position the right-hand axle assembly at front
crossmember. Install the boot on the shaft so the
boot seats in the grooves. Install the pivot bolt Steering Knuckle
that secures the axle assembly to front
crossmember. Tighten bolt to 149-201 N·m SPECIAL SERVICE TOOL(S) REQUIRED
(110-148 Ib-ft). Description Tool Number
5. Install shock absorber mounting plate, front leaf U-Joint Tool T74P-4635-C
spring and axle assembly using two U-bolts.
4WD Ball Joint Tool T80T-30 1O-A
Tighten bolts to 113-153 N·m (83-113Ib-ft).
Pitman Arm Puller T64P-3590-F

ALL RIGHTS RESERVED
Removal 2. Disconnect the steering linkage, if necessary,

1. Remove the front wheel spindle (3105) and the from the knuckle. Refer to Section 11-03 in the
right and left shaft and joint assembly as Body, Chassis Manual.
Steering Knuckle Installation
Part Part
1 3B177 Pivot Bushing 5 3049 Front Suspension Upper Ball
2 3B403 Axle Arm Joint
3 3050 Front Suspension Lower Ball 6 3130 Knuckle
Joint 7 2K004 Front Disc Brake Rotor
4 38440 Camber Adapter Shield
8 3105 Front Wheel Spindle
(Continued)
ALL RIGHTS RESERVED
3. Remove the cotter pin from the stud of the front 6. Place steering knuckle in vise and remove snap
suspension upper ball joint (3049). Loosen the ring from bottom ball joint socket if so equipped.
nut on the top stud and the bottom nut inside the 7. Remove plug from U-Joint Tool T74P-4635-C and
steering knuckle. Remove the top nut. replace with Plug T80T-3010-A4.
PLUG
~-----~ T80T-3010-A4
E9731·A
8. Assemble U-Joint Tool T74P-4635-C and

Receiving Cup T80T-30 10-A2 for F-150 and
F-250.
4. Sharply hit the top stud with a plastic or rawhide
hammer to free the knuckle from the axle arm.
Remove and discard bottom nut. Use new nut
upon assembly.
5. Remove camber adjuster by hand or if difficulty is
encountered use Pitman Arm Puller T64P-3590-F.
Note the orientation of the camber adjuster
to make sure of the same camber setting.
RECEIVING CUP
T80T-3010-A2
(F-150-250, BRONCO) E4213-F
9. NOTE: Always remove front suspension lower
ball joint first.
Turn forcing sere'., clockwise until front
suspension lower ball joint is removed from
steering knuckle.
10. Repeat procedure and remove front suspension
upper ball joint.
Installation
1. Clean steering knuckle bore and insert front
suspension lower ball joint as straight as
possible.
ALL RIGHTS RESERVED
2. Assemble U-Joint Tool, Receiving Cup

T80T-30 10-A3 and Installing Cup D81 T-30 10-A REPLACER
or equivalent to replace the front suspension T80T-3010-A1
lower ball joint on F-150-250 and Bronco with
Dana 44.
E4214-E
INSTALLING CUP 6. Assemble knuckle to axle arm assembly. Install

081 T-301 O-A E9732·A camber adjuster on the stud of the front
suspension upper ball joint with the arrow pointing
3. NOTE: If ball joint cannot be installed to the outboard for "positive" camber, pointed inboard
proper depth, realignment of Receiving Cup for "negative" camber.
T80T-3010-A3 will be necessary. Install the snap 7. Install new nut on bottom socket finger-tight.
ring on the front suspension lower ball joint. Install and tighten nut on top socket finger-tight.
Assemble U-Joint Tool, Receiving Cup Tighten bottom nut to 47 N·m (35Ib-ft).
T80T-30 10-A3 and Receiving Cup D81 T-30 10-A
8. NOTE: Do not loosen top nut to install cotter pin.
or equivalent, to replace the front suspension
lower ball joint on the Dana 50. Tighten top nut to 136 N·m (100 Ib-ft), then
advance nut until castellation aligns with cotter
pin hole. Install cotter pin.
9. Retighten bottom nut to 150 N·m (111 Ib-ft).
10. Install the front wheel spindle and the right and left
shaft and joint assembly as described in this
section.
Spindle, RH and LH Shaft and Joint Assembly

E9733-A Impact Slide Hammer T50T-100-A
Bearing Cup Puller T77F-1102-A
4. Turn forcing screw clockwise until front
Spindle Bearing Replacer T80T-4000-R
suspension lower ball joint is firmly seated.
Spindle Bearing Replacer T80T-4000-S
5. To install front suspension upper ball joint, Driver Handle T80T-4000-W
assemble the C-Frame, Receiving Cup
Spindle Seal Replacer T92T-4000-A
T80T-30 10-A3 and Replacer T80T-30 1O-A 1 and
repeat Step 4.
Removal
2. Remove the wheels (1007) and tires. Refer to
3. On vehicles equipped with four-wheel anti-lock
brakes, remove the front brake anti-lock sensor
(2C204) from the steering knuckle. Refer to
Section 06-09B in the Body, Chassis Manual.

ALL RIGHTS RESERVED
4. CAUTION: After removal, the disc brake

caliper (2B 120) must be wired to the frame
or otherwise supported to prevent
suspending the disc brake caliper by the
flexible hose. If securing the disc brake
caliper is not practical, disconnect the brake
hose from the disc brake caliper. Plug the
hose end to prevent fluid loss and entry of air
into the system. Upon installation of the disc
brake caliper, bleed the brake system as
described in Section 06-00, in the Body,
Chassis Manual.
Remove the disc brake caliper. Refer to Section
06-03 in the Body, Chassis Manual. Securely wire
the disc brake caliper to the frame.
Spindle and LH Shaft and Joint Installation, Typical
Part Part
1 3B403 Axle Arm (LH) 8 3049 Front Suspension Upper Ball
2 3219 Shaft Joint
3 1175 Rolling Diaphragm Seal 9 3A050 Nut
4 3249 Front Axle Shaft Universal 10 3K050 Snap Ring
Joint 11 3050 Front Suspension Lower Ball
5 87747-S2 Filler Plug Joint
6 3A049 Nut 12 2K004 Front Disc Brake Rotor
Shield
7 72035-S Pin
(Continued)
(Continued)

ALL RIGHTS RESERVED
Part Part
13 3299 Integral Spacer / Seal 18 4222 Differential Bearing Cup
14 3123 Caged Needle Bearing 19 1102 Rotor
15 35704 Nut, Dana 20 1102 Hub
16 3105 Front Wheel Spindle 21 3130 Steering Knuckle Assembly
17 4221 Differential Bearing 22 1190 Wheel Bearing Seal
(Continued)
RH Shaft and Joint Assembly Installation, Typical
&372-0
Part Part
1 1175 Rolling Diaphragm Seal 5 3A466 Slip Yoke and Stub Shaft
2 3B400 Camber Adjuster 6 38403 Left Support Arm
3 38402 Right Support Arm 7 3A429 Rubber 800t
4 38478 Keystone Clamp 8 3219 Right Shaft and Joint
(Continued)
5. Remove hub locks, wheel bearings, and locknuts. 8. Remove the nuts retaining the front wheel spindle
Refer to Section 05-03C. to the steering knuckle. Tap the front wheel
6. Remove the front disc brake hub and rotor (1102) spindle with a nylon or rawhide hammer to jar the
and front wheel bearing (1216) from the front front wheel spindle from the knuckle. Remove the
wheel spindle (3105). front disc brake rotor shield (2K004).
7. Remove the outer spindle hub rolling diaphragm
seal for F-150 and Bronco only. If necessary, pry
off using a screwdriver.

ALL RIGHTS RESERVED
9. On the left side of the vehicle remove the shaft 12. Place the front wheel spindle in a vise on the
and joint assembly by pulling the assembly out of second step of the front wheel spindle. Wrap a
the carrier. shop towel around the front wheel spindle or use
a brass-jawed vise to protect the front wheel
spindle.
13. Remove the integral spacer / seal and needle
bearing from the front wheel spindle with Impact
Slide Hammer T50T-1 OO-A and Bearing Cup
Puller T77F-11 02-A.
SEAL AND
BEARING
~E9083.A 14. Inspect the sealing surfaces of the front wheel

spindle for severely corroded, pitted, worn or
E7132-B
10. On the right side of the carrier, remove and galled sealing surfaces. Replace front wheel
discard the keystone clamp from the shaft and spindle if damaged.
joint assembly and the stub shaft.
11. Slide the rubber boot onto the stub shaft and pull
the shaft and joint assembly from the splines of
the stub shaft.
E7133-1A
15. Inspect the outer shaft of the axle shaft assembly

for corroded, pitted, worn or galled surfaces in
the inner oil seal or needle bearing areas. If
E5420-B damaged, replace the outer shaft. Repair axle
shaft U-joint. Refer to Section 05-01.
Part Installation
Item Number Description 1. Clean all dirt and grease from the bearing bore of
1 3219 Shaft and Joint Assembly the front wheel spindle. Bearing bores must be
2 3B478 Keystone Clamp free from nicks and burrs.
3 3A429 Boot
4 3220 Shaft and Joint Assembly

ALL RIGHTS RESERVED
2. NOTE: Replacement spindle bearings are

shipped with a corrosion-preventive gel. This is
not a lubricant. The bearing must be cleaned and
replaced with the specified lubricant.
Install a new needle bearing with writing facing
outward in the bore of the front wheel spindle with
Spindle Bearing Replacer TBOT-4000-R on the
Dana 50, or TBOT-4000-S for the Dana 44 and
Driver Handle TBOT-4000-W. Lubricate the SPINDLE SEAL
bearing with High Temperature 4x4 Front Axle INSTALLER
and Wheel Bearing Grease EBTZ-19590-A or
ESA-M 1C 19B-A.
FRONT WHEEL
SPINDLE
3106
DRIVER HANDLE
T80T-4000-W
SPINDLE BEARING
REPLACER E8789-C
'--""""-'-_ _ T80T-4000-R
(DANA 50) 4. For F-150 and Bronco only, install outer spindle
T80T-4000-S hub rolling diaphragm seal. Seat the rolling
(DANA 44)
diaphragm seal by lightly tapping on the inner
sheet metal lip of the seal with a Driver Handle
TB3T-3132·-A 1, and a hammer to make sure it is
sealed squarely.
E421S-C
3. Install a new integral spacer needle bearing seal.

Pack bearing and spindle hub seal with grease.
Install seal with Seal Replacer T92T-4000-A and
Driver Handle TBOT-4000-W for Model 50. For
Model 44, use Driver Handle TBOT-4000-W and a
suitable seal replacer.
Installation of Spindle Roiling Diaphragm Seal - F-150 and Bronco Only
SPINDLE SEAL INSTALLER

3105 (USE WITH
SPINDLE ROLLING DRIVER HANDLE
DIAPHRAGM T83T-3132-A)
SEAL-3254
E9785-A

ALL RIGHTS RESERVED
5. Install the rolling diaphragm seal on the axle 8. Align the missing spline in the slip-yoke barrel with
shaft. The lip of the seal should face toward the the gapless male spline on the shaft and joint
front wheel spindle. Seat the rolling diaphragm assembly.
seal by lightly tapping on the inner sheet metal lip 9. Slide the right shaft and joint assembly through
of the seal with a seal insert tool, Driver Handle the knuckle and into the slip-yoke making sure the
T83T-3132-A 1, and a hammer to make sure it is splines are fully engaged.
sealed squarely.
10. Slide the boot over the assembly and crimp the
keystone clamp using Keystone Clamp Pliers
T63P-9171-A.
11. On the left side of the carrier slide the shaft and
joint through the knuckle and engage the splines
on the shaft in the carrier.
12. NOTE: Make sure the grease seal lip totally
encircles the front wheel spindle.
Install the front disc brake rotor shield and front
wheel spindle onto the steering knuckle, both
sides. Install and tighten the nuts of the front
wheel spindle to 81 N·m (60 Ib-ft) for Model 50
axle or 47 N·m (35Ib-ft) for Model 44 axle.
13. Install the front disc brake hub and rotor on the
front wheel spindle. Install the outer wheel bearing
into the cup. Refer to Section 05-03C.
14. Install the wheel bearing, locknut, front wheel
outer bearing retainer washer (1195), snap ring
and locking hubs per Section 05-03C.
15. Install the disc brake caliper. Refer to Section
E9786-A 06-03 in the Body, Chassis Manual.
16. On vehicles equipped with four-wheel anti-lock
6. Lightly coat the thrust face of the lips of the seal brakes, install the front brake anti-lock sensor on
bore of the front wheel spindle and the Rolling the steering knuckle. Refer to Section 06-09B in
Diaphragm Seal on the axle shaft with High the Body, Chassis Manual.
Temperature 4x4 Front Axle and Wheel Bearing
Grease E8TZ-19590-A or equivalent meeting
Ford specification ESA-M1C198-A.
Slip-Yoke, RH, and Stub Shaft Assembly,
Carrier, Carrier Oil Seal and Bearing

Bench Mounted Holding Fixture T57L-500-B
Differential Housing Spreader Adapter T80T-4000-B
Needle Bearing Replacer T83T-1244-A
Removal
E7137·B
1. Remove the nuts and U-bolts connecting the
7. NOTE: Since the splines on the shaft are phased, driveshaft to the yoke. Disconnect the driveshaft
there is only one way to assemble the right shaft from the yoke. Wire the driveshaft out of the way,
and joint through the knuckle and into the so it will not interfere in the carrier removal
slip-yoke. process.
On the right side of the carrier, install the rubber
boot and new keystone clamps on the stub shaft
slip-yoke.

ALL RIGHTS RESERVED
RH Slip-Yoke and Stub Shaft Assembly, Carrier, Carrier Oil Seal and Bearing
E7'38-B
Part Part
1 3A429 Boot 7 3254 Seal
2 3L387 Slip Yoke 8 3B403 Left Axle Arm
3 3249 Universal Joint 9 3254 Needle Bearing
4 3C123 Seal 10 3N387 Stub
5 3167 C-Clip 11 3B478 Keystone Clamps
6 3010 Carrier 12 358035-S Fill Plug
(Continued) 13 3C323 Bolt
2. Remove both front wheel spindles (3105) and the 4. Separate the carrier from the support arm.
left and right shaft and U-joint assemblies. Refer Remove the carrier from the vehicle.
to Spindle, RH and LH Shaft and U-Joint
Assembly Removal and Installation in this section.
3. NOTE: When performing the next step, position a
drain pan under the carrier assembly to catch the
lubricant when the carrier is separated from the
arm.
Support the carrier with a suitable jack and
remove the bolts retaining the carrier to the
support arm.

ALL RIGHTS RESERVED
5. Place the carrier in Bench Mounted Holding 8. Remove the oil seal and caged needle bearings at
Fixture T57L-500-B and Differential Housing the same time, using Impact Slide Hammer
Spreader Adapters T80T-4000-B. T50T-100-A and Collet (part of Blind Hole Puller
Set D80L-100-A or equivalent) as shown.
Discard the seal and needle bearing.
IMPACT
~P----SLIDE HAMMER
T60T-1OQ-A
COLLET
•.....---OBOL-100-A
6. Rotate the slip-yoke and shaft assembly so the E5383-B

open side of the snap ring is exposed as shown.
Remove the snap ring from the shaft. Installation
1. Make sure the bearing bore is free from nicks and
burrs. Install a new caged needle bearing on
Needle Bearing Replacer T83T-1244-A with the
manufacturer name and part number facing
outward toward the tool. Drive the needle bearing
until it is seated in the bore using Driver Handle
T80T-4000-W.
.,/
E&38Z-e
7. Remove the slip-yoke and shaft assembly from
the carrier.

ALL RIGHTS RESERVED
2. Coat the seal with High Temperature 4x4 Front 6. NOTE: The bead should be continuous and
Axle and Wheel Bearing Grease E8TZ-19590-A should not pass through or outside the holes.
or equivalent meeting Ford specification NOTE: The carrier must be installed on the
ESA-M 1C 198-A. Drive the seal into the carrier support arm within five minutes after applying the
using Needle Bearing Replacer T83T-1244-A. RTV sealant.
Apply a bead of Silicone Rubber D6AZ-19562-AA
(clear) or -BA (black) or equivalent meeting Ford
specifications ESB-M4G92-A and
ESE-M4G 195-A, in a bead 6mm (1 / 4-inch) wide.
7. Position the carrier on a suitable jack. Install
carrier in position on the support arm using guide
pins to align. Install the attaching bolts and
hand-tighten. Tighten the bolts in a clockwise or
counter-clockwise pattern to 54 N·m (40 Ib-ft).
8. Install support arm tab bolts to side of carrier.
Tighten bolts to 135 N·m (100 Ib-ft).
9. Install both front wheel spindles and the left and
right shaft and joint assemblies as described in
the removal and installation portion of this
section.
10. Connect the driveshaft to the yoke. Install the
nuts and U-bolts and tighten to 11-20 N·m (8-15
E5385·1A
Ib-ft).
3. Install the slip-yoke and shaft assembly into the
carrier so the groove in the shaft is visible in the
differential case.
4. NOTE: Do not tap on the center of the snap ring. Differential Seal, LH
This may damage the snap ring.
Install the snap ring in the groove in the shaft.
Force the snap ring into position with a Description Tool Number
screwdriver as shown. Remove the carrier from
Puller T58-101-B
the holding fixture.
Differential Axle Seal Replacer T80T-4000-H
Removal
1. Remove the front wheel spindle (3105) and left
shaft assembly as described in this section.
2. Pull out the seal with Puller T58L-101-B. Remove
and discard seal.
Installation
1. Lightly coat a new seal with High Temperature
4x4 Front Axle and Wheel Bearing Grease
E8TZ-19590-A or equivalent meeting Ford
specification ESA-M 1C 198-A.
2. Install seal on the Differential Axle Seal Replacer
T80T-4000-H.
3. Slide the seal and tool into the carrier housing
bore. Seat the seal with a nylon or rawhide
./ hammer.
E5388·1A
5. Clean all traces of gasket RTV sealant from the

surfaces of the carrier and support arm and make
sure the surfaces are free from dirt and oil.

ALL RIGHTS RESERVED
:>S-03A-2S Axle, Front Drive, Dana Models 44 and SO OS-03A-25
~EMOVAL AND INSTALLATION (Continued)
4. Install the front wheel spindle and left shaft 2. Install the axle as described in this section under
assembly. Refer to Spindle, RH and LH Shaft and Front Driving Axle Installation.
Joint Assembly Removal and Installation in this
section.
DIFFERENTIAL AXLE SEAL

REPLACER-T80T-400o-H
E4101-B
Axle Housing Pivot Bushing (IFS Front

Drive Axle) SCREW
T78P-5838-A1 M11..18
Suspension Bushing Service Set T78P-5638-A
Front Suspension Bushing Tool T80T-5638-A
Cardan-Type U-Joints
Removal Refer to Section 05-0 1.
1. Remove axle. Refer to Dana Four-Wheel Drive
Front Orive Axle Removal and Installation in this
section.
2. Install Suspension Bushing Service Set Carrier
T78P-5638-A 1, Bushing Remover T80T-5638-A 1
and Receiver Cup T78P-5638-A3 onto the pivot SPECIAL SERVICE TOOL(S) REQUIRED
bushing. Turn the forcing screw and remove the
pivot bushing.
Companion Flange Remover T65L-4851-A
Differential Housing Spreader Adapter T80T-4000-B
LH. AXLE
HOUSING NOTE: 44 Series front drive axle ratios 3.07 to 1 up to
3.54 to 1 incorporate a thick differential case flange
and a thin ring gear. Ratios 4.09 to 1 and 4.10 to 1
incorporate a thin differential case flange and a thick
ring gear.
PIVOT
BUSHING RECEIVER CUP
REMOVER T78P-5638--A3
TBOT-5638-A1 E4112-18
Installation
1. Place pivot bushing in axle housing. Install
Receiver Cup T78P-5638-A2, Forcing Screw THIN FLANGE
T78P-5638-A 1 and Bushing Replacer THICK RING
T80T-5638-A2 into housing and install bushing. GEAR-3222 THICK FLANGE E4844-B
1995 ~-150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
Disassembly 4. Remove the differential case from the carrier. It

1. Remove carrier. Refer to Slip-Yoke, RH and Stub may be necessary to pry the differential case
Shaft Assembly, Carrier, Carrier Oil Seal and from the carrier with pry bars. Use caution to
Bearing Removal and Installation in this section. avoid damaging any machined surfaces. Remove
and tag differential bearing cups (4222) to
2. Place the carrier in a holding fixture, remove and indicate from which side of the carrier they were
clean all gasket surfaces and remove the bearing removed. Remove the spreader tool.
caps. Note the matched numbers or letters
stamped on the cap and carrier. These numbers 5. Turn the nose of the carrier up. Hold the end yoke
or letters must be matched upon assembly. with Holding Tool T78P-4851-Aand remove the
pinion nut and washer from the differential pinion
shaft (4211).
6. Remove the end yoke with Yoke Remover
T65L-4851-B. If the yoke shows any signs of
wear in the area of seal contact, replace the
yoke.
7. CAUTION: Be careful not to damage the
pinion bearing preload shims located on the
splined end of the pinion. If damaged,
replace with shims of equal thickness. Do not
lose the shims.
Remove the drive pinion by tapping on the drive
pinion shaft with a rawhide or nylon hammer.
Catch the pinion to prevent damage to the pinion.
8. Remove the pinion seal from the carrier bore by
using Bearing Cup Puller T77F-11 02-A and
Impact Slide Hammer T50T-1 OO-A. Replace the
pinion seal with a new one during assembly.
9. Remove the outer pinion bearing and the oil
slinger from the carrier input bore.
10. Remove the pinion bearing preload shims.
E7152·C Remove all shims from the carrier. Replace any
damaged shims during assembly. Shims are
3. Mount Differential Housing Spreader available in thicknesses of 0.08,0.13,0.25 and
TOOL-4000-E or equivalent and Differential 0.76mm (0.003, 0.005, 0.010 and 0.030 inch).
Housing Spreader Adapter T80T-4000-B on
carrier. Place Dial Indicator TOOL-4201-C or 11. Remove the inner pinion bearing cup and baffle
equivalent on the carrier and spread the housing. using Pinion Bearing Cup Remover D81T-4628-C
Do not spread the carrier over 0.25mm (Model 44 axles) or D81 T-4628-D (Model 50
(0.010 inch). axles) and Driver Handle D81L-4000-A or
equivalents. Drive the bearing cup out of the bore.
DIFFERENTIAL PINION BEARING
HOUSING DIAL INDICATOR CUP REMOVER
SPREADER WITH BRACKETRY ~---D81T-4828-e INNER (MODEL 44)
TOOL-4000-E D81T-4628·D INNER (MODEL 50)
TOOL-4201 -C D81T -4828-0 OUTER (MODEL 44 AND 50)
E4841-1A
12. Turn the nose of the carrier down and remove the
outer pinion bearing cup. Drive the cup from the
carrier using Pinion Bearing Cup Remover
D81 T-4628-D (Model 44 and 50 axles) and
SPREADER
ADAPTER
Driver Handle D81 L-4000-A or equivalents.
TSOT-4000-8
E4845-C

ALL RIGHTS RESERVED
13. Remove the differential case bearings and shims SELECTIVE SHIM SIZES
from the case. Place Step Plate D80L-630-5 or mm Inches
equivalent under bearing to protect the bearing.
Install Universal Bearing Remover D81L-4220-A 1.35 .053
or equivalent and remove the bearing as shown. 1.40 .055
Turn the case over and remove the other bearing. 1.45 .057
1.50 .059
1.55 .061
PINION AND CARRIER 1.60 .063
BEARING PULLER
081 L-4220-A 1.65 .065
1.70 .067
1.75 .069
1.80 .071
1.85 .073
~...----_._.,,--
II
/(
E4848-B
14. Wire the shims, bearing cup and cone together

and identify from which side of the case they
were removed. If any shims are damaged,
replace with new shims upon assembly.
15. NOTE: Whenever removing the bolts of the
differential ring gear, discard the bolts and
replace with new bolts upon assembly. 17. Inspect all parts for damage and replace as
required.
Place a few shop towels over the vise to prevent
the ring gear teeth from being nicked, after it is
free from the case. Place the case in a vise.
Remove the ring gear bolts. Tap the ring gear with Total Differential Case End Play
a rawhide hammer to free it from the case.
Remove the case and differential ring gear and Assembly
pinion from the vise. 1. Attach the differential ring gear to the differential
16. NOTE: Shim/slinger is located between the case using new bolts. Tighten bolts alternately
pinion gear head and the differential pinion and evenly to 95-122 N-m (70-90 Ib-ft) or
bearing (4630). Be careful not to damage the 129-142 N·m (95-105 Ib-ft) using grade 9 bolts.
shim / slinger when removing the bearing cone. If
the shim / slinger is damaged, measure the
thickness and replace with shim / slinger of equal
thickness. Refer to the following chart.
Remove the bearing and selective shims from the
drive pinion with Universal Bearing Remover
081 L-4220-A or equivalent.

ALL RIGHTS RESERVED
05-03A-28 Axle, Front Drive, Dana Models 44 and 50 05-03A-2f
2. Clean the trunnions on the differential and install 5. NOTE: The reading obtained in this step indicates
Master Bearing Set D81 T-4222-BR or equivalent the amount of shims needed behind the
for Model 44 axles, or D81T-4222-C or differential side bearings to take up total
equivalent for Model 50 axles onto the differential clearance between the differential bearing and
case. Remove all burrs and nicks from hubs so differential case. This reading will be used under
master bearings rotate freely. Gear Tooth Contact Pattern Check in this section.
Force the differential case away from the dial
indicator as far as it will go. Repeat this
procedure until the same reading is obtained.
Record the dial indicator reading.
6. Remove the differential case from the carrier. Do
not remove the master differential bearings at this
time.
Drive Pinion Installation

Two separate adjustments affect tooth contact of the
drive pinion and ring gear:
• pinion depth (location)
• backlash
The pinion locating shim is installed between the
differential pinion bearing (4630) and the head of the
pinion gear.
This shim pack and inner oil slinger and oil baffle
3. NOTE: Dial indicator should have a minimum
control the position of the pinion.
travel capability of 5.08mm (0.200 inch).
Place the differential case into carrier (without • Increasing shim thickness moves the pinion toward
pinion). The differential case should move freely the ring gear.
in the carrier. Mount Dial Indicator D78P-4201-B • Decreasing shim thickness moves the pinion away
or TOOL-4201-C or equivalents against the from the ring gear.
differential case flange as shown. Locate the tip
of the indicator on the flat surface of one ring gear
bolt.
4. Force the differential case toward the dial
indicator as far as possible and zero the dial
indicator with force still applied.
IN MM
.003 (.08)
.005 (.13)
DIAL
INDICATOR .010 (.25)
D78P-4201·B OR .030 (.76)
TOOL-4201-C
IN MM
.063 1.35
.055 1.40
.051 1.45
.059 1.50
.061 1.55
.063 1.60
.065 1.65
.067 1.10
.069 1.75
.071 1.80
.073 1.85
E4117-C
E9084-B

ALL RIGHTS RESERVED
Differential ring gear and pinions are supplied in On the face of each drive pinion is marked a plus figure
matched sets with standard or metric markings. (+), a minus figure (-) or a zero (0). These figures
indicate the position for each gearset. The position is
BUTTON END (MAY NOT
determined by the amount of drive pinion shims
BE A GROUND SURFACE) DIFFERENTIAL between the pinion bearing cup and carrier bearing
RING GEAR bore, or if selective shim is used, between the inner
AND PINION pinion bearing cone and pinion gear head. Refer to the
3222
following charts.
STANDARD PINION E7117-E
New Pinion Marking (EngIl8h)

Old Pinion
Marking -4 ·3 ·2 -1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003
0 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004
-1 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005
-2 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006
-3 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007
-4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008
TE4091A

Old Pinion
Marking ·10 ·8 ·5 ·3 0 +3 +5 +8 +10
+10 +.20 +.18 +.15 +.13 +.10 +.08 +.05 +.03 0
+8 +.18 +.15 +.13 +.10 +.08 +.05 +.03 0 -.03
+5 +.15 +.13 +.10 +.08 +.05 +.03 0 -.03 -.05
+3 +.13 +.10 +.08 +.05 +.03 0 -.03 -.05 -.08
0 +.10 +.08 +.05 +.03 0 -.03 -.05 -.08 -.10
-3 +.08 +.05 +.03 0 -.03 -.05 -.08 -.10 -.13
-5 +.05 +.03 0 -.03 -.05 -.08 -.10 -.13 -.15
-8 +.03 0 -.03 -.05 -.08 -.10 -.13 -.15 -.18
-10 0 -.03 -.05 -.08 -.10 -.13 -.15 -.18 -.20
TE4092A
If the old ring and pinion shim pack is used, measure If a new ring gear and drive pinion is being installed,
the slinger and baffle and each shim separately and note the plus (+), minus (-) or zero (0) marking on the
add each shim measurement to total the original button of the pinion. Refer to the charts. Add or
measurement. Replace the old shims with new shims subtract shims, according to the chart to compensate
that equal this measurement. for differences between the old and new pinion.

ALL RIGHTS RESERVED
For example, if a new pinion is marked "positive" +3 2. Install inner and outer differential drive pinion
(+8 metric) and an old pinion is marked "0," then bearing cups (4616) with Threaded Drawbar
.008mm (.003) less shim pack thickness is required T75T-1176-A and Pinion Bearing Cup Replacers
between the inner differential pinion bearing and the T80T-4000-D for Model 44 axles and
pinion head. T80TF-4000-F for Model 50 axles (inner
A new ring gear and drive pinion is always installed as differential drive pinion bearing cup) and
a matched set and never separately. Make sure that T80T-4000-E (outer differential drive pinion
the same matching number appears on both the bearing cup).
drive pinion and ring gear.
Install the correct shim pack of the drive pinion and
place the pinion in the carrier. Check pinion depth.
Depth Gauge Check

Threaded Drawbar T75T·1176·A
Pinion Bearing Cup Replacer T80T·4000·D, F
Pinion Bearing Cup Replacer T80T·4000·E
Pinion Bearing Cone Replacer T53T·4621·B
,
Axle Bearing / Seal Plate T75L·1165·B
I
1. NOTE: If any of the gauge surfaces become
nicked, the high spots must be removed with a -------i----.. - --
medium India oilstone to eliminate erroneous
readings.
i
Refer to the illustration for the correct tools for E4843-D
the particular axles.
Part
1 T80T-4000-E Pinion Bearing Cup Replacer
- Outer (Models 44 and 50)
2 T80T-4000-D Pinion Bearing and Cup
Replacer -Inner
(Model 44)
3 T80T-4000-F Pinion Bearing Cup Replacer
- Inner (Model 50)
E4118-D 4 4616 Differential Drive Pinion
Bearing Cup, Inner
Part 5 4616 Differential Drive Pinion
Bearing Cup, Outer
6 T75T-1176·A Threaded Drawbar
1 T80T·4020-F42 Gauge Block
(Part of T80P-4020-A) 3. Place a new differential pinion bearing (4630)
2 T76P-4020-A3 ;
Aligning Adapter over the proper aligning adapter and insert into
3 T80T-4020-F43 Screw (Part of T80P-4020-A) the pinion bearing retainer assembly.
4 4621 Differential Pinion Bearing 4. Place the front differential pinion bearing (4621)
5 T76P-4020-A 11 Handle (new or used if in good condition) into the
(Part of T80P-4020-A) differential drive pinion bearing cup in the carrier
6 4621 Differential Pinion Bearing and assemble the handle onto the screw and
7 T78P-4020-A 15 Gauge Disc hand tighten.
(Part of T80-4020-A)
Note the 3 /8-inch square drive in the handle to be
8 D80T-4020-F48 Gauge Disc used for obtaining the proper differential pinion
(Part of T80-4020-A)
bearing preload.
1995 F·150, F·250, F·350, Bronco, F·Super Duty P.owertrain, Drivetrain July 1994
ALL RIGHTS RESERVED

pinion bearing bore. Install the bearing caps and
tighten to proper specifications listed at the end
of this section. To preload the differential pinion
bearing, tighten the handle to 2.3-4.5 N·m (20-40
Ib-in).
6. NOTE: The feeler gauge fit between the gauge
tube and the gauge block should be a slight
drag-type feeling.
NOTE: If the service pinion gear is marked with a
plus (+) reading, this amount must be subtracted
from the thickness dimension obtained in Step 6.
For example: +2 (-0.002).
Using a feeler gauge tool or shims, select the
thickest feeler shim that will enter between the
gauge tube and the gauge block. Insert the feeler
gauge or shims directly along the gauge block to
insure a correct reading.
7. After the correct shims or feeler gauge feel is
obtained, check the reading and this is the
thickness of shim required providing that upon
inspection of the service pinion gear, the button is
etched UO."
If the service pinion gear is marked with a minus
(-) reading, this amount must be added to the
thickness dimension obtained in Step 6. For E4842·E
example: -2 (+0.002).
In addition, use the exact same new differential Part
pinion bearing used in the previous steps. Item Number Description
8. Measure shims with a micrometer to verify the 1 3222 Drive Pinion
shim size. Place the correct size selective shim 2 4067 Shim
on the pinion and press on the differential pinion 3 4630 Differential Pinion Bearing
bearing. Use Pinion Bearing Cone Replacer 4 T75L-1165-B Axle Bearing Seal Plate
T53T-4621-8 for Model 44 axles and Axle
5 T53T-4621-B Pinion Bearing Cone
Bearing/Seal Plate T75L-1165-B as shown. Replacer
9. After following these procedures, continue to

build the remaining components with proper
pinion and differential bearing preload torques
and ring gear backlash.
Bearing Cup and Drive Pinion Installation

Pinion Bearing Cup Replacer T80T-4000-0, F
Pinion Bearing Cup Replacer T80T-4000-E
Pinion Bearing Cone Replacer T53T-4621-B
Axle Bearing I Seal Plate T75L-1165-B
1. Clean the bore. If installed, remove the differential

drive pinion bearing cup (4616).

ALL RIGHTS RESERVED
05-03A-32 Axle, Front Drive, Dana Models 44 and 50 05·03A·32
2. NOTE: Be careful not to misalign the rear axle

pinion bearing cup (4628). COMPANION
FLANGE
Place the oil baffle first and the required amount REPLACER
of differential pinion bearings (4630) in the bore of T83T-4851-A
the differential pinion bearing and drive the rear
axle pinion bearing cup in place with Inner Pinion
Bearing Cup Replacer T80T-4000-D (Model 44
axle) or T80T-4000-F (Model 50 axles) and
Forcing Screw T75T-1176-A.
3. Place the differential drive pinion bearing cup into
the carrier and drive in place with Outer Pinion
Bearing Cup Replacer T80T-4000-E. Install
Threaded Drawbar T75T-1176-A and draw the
cups into the bore. E4223-e
4. Lubricate the ends of outer differential pinion
5. Rotate pinion nut with an inch-pound torque
bearing rollers with Premium Long-Life Grease
wrench. Rotating torque should be 2.26-4.51 N·m
XG-1-C or ..K or equivalent meeting Ford
(20-40 Ib-in). To increase preload, remove shims.
specification ESA-M1C75-B.lnstall the outer
.To decrease preload, add shims.
differential pinion bearing (4621) in place in outer
differential drive pinion bearing cup. 6. Install the yoke with Companion Flange Replacer
T8"3T-4851-A.lnstall washer and nut and tighten
5. Install the inner differential pinion bearing and
nut to 244-271 N·m (180-200 Ib-ft).
pinion position shim on the pinion. Drive the
differential pinion bearing on the drive pinion shaft
until fully seated using Pinion Bearing Cone
Replacer T53T-4621-B (Model 44 axles) and
Axle Bearing/Seal Plate T75L-1165-B. Differential Case
Disassembly
1. Place case in vise and drive out roll pin that .
retains the differential pinion shaft (4211) to
Drive Pinion Preload Check case.
SPECIAL SER·VICE TOOL(S) REQUIRED
Companion Flange Replacer T83T-4851-A
1. Measure original preload shims and replace with

new shims of equal size.
2. Install the pinion into the carrier.
3. Install new preload shims over the pinion. Install
the outer differential drive pinion bearing cup
(4616) and oil slinger and seal.
4. Assemble end yoke, washer and deflector, on
drive pinion shaft, and align with Companion
Flange Replacer T83T-4851 ..A and Companion
Flange Holding Tool T78P-4851-A to seat the
yoke. Install an old pinion nut and tighten nut to
272-298 N·m (200-220 Ib..ft).
E7153·1A
Use the old pinion nut until preload is verified. If
rotating torque is within specification, then install
the new pinion nut and tighten to specification.

ALL RIGHTS RESERVED
2. Remove differential pinion shaft with a drift. 3. Hold differential side gears (4236) in place in
case with one hand and install pinion gears and
differential pinion thrust washers with other hand.
Rotate the side gears and differential pinion gears
until the holes in the differential pinion thrust
washers and differential pinion gears line up
exactly with the holes in the case.
4. Insert the pinion shaft in the case. Make sure the
hole for the pinion roll pin in the shaft lines up with
the holes for the roll pin in the case.
5. Insert roll pin. Peen some metal of the case over
the roll pin to lock in two places 180 degrees
apart. Note the location of the slot in the roll pin.
Peen 90 degrees from slot.
3. Rotate the pinion gears and differential side gears

until the differential pinion gears turn to the Differential Case Assembly to Carrier
windows of the case. Remove differential pinion
gears and differential pinion thrust washers SPECIAL SERVICE TOOL(S) REQUIRED
(4230).
4. Lift differential side gears and differential side
gear thrust washers (4228) from case. Dial Indicator with Bracketry TOOL-4201-C
Differential Side Bearing Replacer T80T-4000-J
Pinion Bearing Cone Replacer T53T-4621-B
Pinion and Ring Gear Backlash

1. Assemble ring gear to case. Use new grade 9
bolts. lighten bolts alternately and evenly to
95-122 N·m (70-90 Ib-ft) for Model 44 and
129-142 N·m (95-105Ib-ft) for Model 50.
2. Place the case into position in the carrier. Master
bearings should still be installed.
3. Force the case away from the drive pinion gear
until it is completely seated against the cross
bore face of the carrier. Position a dial indicator
so the indicator tip rests on a bolt of the case.
Zero the dial indicator.
E7155-1A
Assembly
1. Inspect differential case parts for signs of wear. If
wear exists on all parts, replace the entire
differential. If one gear shows signs of wear,
replace both pinion gears and differential side
gears as a set.
2. Apply High Temperature 4x4 Axle Grease
specification ESA-M 1C 198-A to differential side
gear thrust washers, hub and thrust face of
differential side gears. Lubricate pinion gears and
differential pinion thrust washers with High
Temperature 4x4 Axle Grease E8TZ-19590-A or
ESA-M1C198-A.

ALL RIGHTS RESERVED
4. Force ring gear against drive pinion gear. Rock 8. To determine the correct amount of differential
ring gear slightly to make sure gear teeth are in bearing shims to be placed on the hub of the drive
contact. Then, force ring gear away from drive pinion side of the differential case, subtract the
pinion gear, making sure the dial indicator returns reading obtained in Step 4 from the Total
to zero. Repeat this procedure until the dial Differential Case End Play. Total case end play
indicator reading is the same. was determined in Steps 3 through 5 of Total
This reading reveals the amount of shims Differential Case End Play. When this amount is
necessary between the case and differential determined, add 0.26mm (0.010 inch) to the
bear_ing (4221) on the ring gear side. amount. This is the required amount of differential
bearing shims to be placed on the hub of the drive
5. Remove the case from the housing. Remove the pinion side of the differential case.
master bearings from the case.
For example, total case end play was 2.30mm
6. As determined in Step 4, place the required (0.091 inch). The reading in step 4 was 1.14mm
amount of differential bearing shims (4067) on the (0.045 inch), and when subtracted from 2.30mm
ring gear hub of the case. For example, if the (0.091 inch) gives 1. 16mm (0.046 inch), 0.26mm
reading in Step 4 was 1. 14mm (0.045 inch), (0.010 inch) is added to give 1.42mm (0.056
place 1. 14mm (0.045 inch) amount of differential inch) amount of differential bearing shims to be
bearing shims on the hub of the ring gear side of placed on the hub of the drive pinion side of the
the differential case. differential case.
7. Install the differential bearing on the hub of the 9. Place the required amount of shims on the hub of
ring gear side of the case. Drive the differential the drive pinion side of the differential case.
bearing onto the hub using Differential Side
Bearing Replacer T80T-4000-J. 10. Install the differential bearing on the hub of the
drive pinion side of the case. Place Step Plate
D80L-630-5 or equivalent on the ring gear side
bearing to protect the differential bearing.
11. Drive the differential bearing onto the hub of the
drive pinion side of the differential case using
Differential Side Bearing Replacer T80T-4000-J.
Place the Pinion Bearing Cone Replacer
T53T-4621-B on the ring gear differential bearing
to prevent damage.
12. Install the differential bearing cups (4222) on the
differential bearings.
13. CAUTION: When performing next step, do
not exceed 0.25mm (O.01 inch).
With the spreader and dial indicator installed on
the differential case, spread the carrier housing.
14. NOTE: Be careful to not nick the teeth of the ring
gear or pinion.
Install the differential case in the carrier. If
necessary use a rawhide or plastic hammer to
seat the case into the carrier housing cross bore.
With partial and non-hunting / partial ring gear and
E4224-C pinion sets, align the marks on the ring gear and
drive pinion if required.
15. Remove the spreader and dial indicator from the
differential case.
16. Install bearing caps and bolts. Make sure the
letters stamped on the caps correspond in both
position and direction with the letters stamped
into the carrier. Tighten bolts to 122 N·m (90
Ib-ft).
17. Rotate the pinion and differential assembly
several revolutions to seat differential bearings.

ALL RIGHTS RESERVED
18. Install Dial Indicator TOOL-4201-C or equivalent SEALER

on the case. Check ring gear and pinion backlash
at three equally spaced points on the ring gear.
Refer to Gear Tooth Contact Pattern Check in this
section for backlash tolerance.
DIAL INDICATOR
TOOL-4201-C
E4226-1 A
21. Mount the differential to the left-hand axle arm

using two guide pins, being careful not to smear
gasket sealant. Install and tighten bolts to 54 N·m
(40Ib-ft).
22. Use new bolts with encapsulated adhesive or
wire brush the old bolts and apply thread-locking
compound Threadlock and Sealer
specification WSK..M2G315-A5 (Type II).
23. Install support arm tab bolts to side of carrier and
tighten to 115-135 N·m (85-100 Ib-ft).
E7158·B
Gear Tooth Contact Pattern Check

1. NOTE: A marking compound mixture that is too
wet will run and smear, too dry a mixture cannot
be pressed out from between the teeth.
To check the gear tooth contact, paint the gear
teeth with the special marking compound.
2. Rotate the ring gear (use a box wrench on the
ring gear attaching bolts as a lever) several
complete revolutions in both directions or until a
clear tooth contact pattern is obtained.
Incorrect adjustment can be corrected by
readjusting the ring gear or the pinion.
4. The following illustration shows acceptable tooth
patterns for all axles. In general, desirable tooth
19. Obtain a gear tooth contact pattern check. Refer patterns should have the following
to Gear Tooth Contact Pattern Check in this characteristics:
section prior to complete reassembly. a. The drive pattern should be fairly well
20. Apply a bead 3. 175-6.35mm (1 /8-1 /4-inch) high centered on the tooth, but may be slightly
and 3. 175-6.35mm (1 /4-1 /2-inch) wide of toward the toe.
Silicone Rubber Sealant D6AZ-19562-AA (clear) b. The coast pattern should be fairly well
or -BA (black) or equivalent meeting Ford covered on the tooth.
specifications ESB-M4G92..A and
ESE..M4G 195-A on the mating surfaces of the c. Some clearance between the pattern and the
carrier mounting face support arm. top of the tooth is desirable.
Allow one hour curing time after the axle carrier is d. There should be no hard lines where the
assembled to the axle arm before installing pressure is high.
lubricant and operating vehicle.

ALL RIGHTS RESERVED
Tooth Patterns
ACCEPTABLE TOOTH PAnERN LIMITS

ANY COMBINATION OF DRIVE AND COAST
TOE PATTERNS SHOWN PERMISSIBLE
TOE
2 8 2
3 7 3
4 COAST U'I&-2A
DRIVE
5. An individual gearset need not conform exactly to

the ideal pattern to be acceptable. Any
combination of drive and coast patterns shown is
acceptable.
ALL RIGHTS RESERVED
6. Since each gearset rolls a characteristic pattern, NOTE: If the patterns are not correct, make the
the patterns shown are considered acceptable changes as indicated. The differential case and drive
and should be used as a guide. The drive pattern pinion will have to be removed from the carrier housing
is rolled on the convex side of the tooth, and the to change a differential bearing shim (4067).
coast pattern is rolled on the concave side. NOTE: When a change in backlash is required,
differential bearing shims should be changed in the
range of 1-1 / 2 times the amount of backlash required
to bring the gears into specification. For example, if
the backlash needed to be changed by .10mm (.004
inch), the differential bearing shims should be changed
by .15mm (.006 inch) as a starting point. The actual
amount of backlash change obtained will vary
depending upon the ratio and gear size.
7. If the drive pinion positioning shims are correct:
• Decreasing backlash moves the ring gear
ROOT closer to the drive pinion. Drive pattern
(convex side of gear) moves slightly lower and
RING GEAR TOOTH
toward the toe. Coast pattern (concave side of
COAST SIDE
HEEL
gear) moves lower and toward the toe.
• Increasing backlash moves the ring gear away.
from the drive pinion. Drive pattern moves
slightly higher and toward the heel. Coast
pattern moves higher and towards the heel.
8. Check ring gear backlash by installing a dial
indicator on the carrier housing. Check ring gear
and pinion backlash at three equally spaced
E8198-B
points on the ring gear. Backlash tolerance is
NOTE: When making drive pinion position changes, 0.13-0.23mm (0.005-0.009 inch) and cannot
drive pinion shims should be changed in the range of vary m at three equally spaced points on the ring
.05mm (.002 inch) to .10mm (.004 inch) until correct gear. Backlash tolerance is 0.13-0.23mm
pattern has been obtained. (0.005-0.009 inch) and cannot vary more are
than 0.08mm (0.003 inch) between the three
The movement of tooth contact patterns with changes points. If backlash is high, the ring gear must be
in shimming can be summarized as follows: moved closer to the drive pinion, by moving
a. Thinner drive pinion shim, with the backlash differential bearing shims to the ring gear side to
set to specification, moves the drive pinion the opposite side. If backlash is low, the ring gear
farther from the ring gear. must be moved away from the drive pinion by
moving differential bearing shims from the ring
b. Thicker drive pinion shim, with the backlash
gear side to the opposite side.
set to specification, moves the drive pinion
closer to the ring gear.

HEEL TOE TOE HEEL
HEEL TOE TOE HEEL
DRIVE PINION SHIM CORRECT.

BACKLASH CORRECT. DECREASE BACKLASH.
THINNER DRIVE PINION
SHIM REQUIRED.
DRIVE PINION SHIM CORRECT.

INCREASE BACKLASH.
BACKLASH CORRECT.
THICKER DRIVE PINION
SHIM REQUIRED.
. El198-8
E8197·B
Worksheet for Calculating Ring Gear Backlash
and Differential Bearing Preload Shims
Steps:

ALL RIGHTS RESERVED
1. Total amount of space measured without gearset TORQUE SPECIFICATIONS (Cont'd)

assembled into carrier (housing) = Measurement
Description N·m Lb·Ft
A
--- Top Ball Joint Stud Nut 136 N·m 100·
2. Total amount of space measured with gearset
assembled into carrier = Measurement B Bottom Ball Joint Stud Nut 123·149 91-110·
--- Spindle to Steering Knuckle Nuts 81
3. Measurement A minus Measurement B = 60
(Both Sides) (Model 50)
Measurement C
--- Spindle to Steering Knuckle Nuts 47 35
After the measurement and calculations have been (Both Sides) (Model 44)
made, assemble the shim packs using the figures
a Requires specific tightening sequence for proper
determined in A, B & C and adjusting the pack as installation. Refer to ball joint installation procedure in this
described below. section.
RING GEAR SIDE:
B = Total shim pack thickness. DANA AXLE ADJUSTMENTS
OPPOSITE SIDE: Description Specification
C+0.010 (0.25 mm) = Total shim pack
Drive Pinion Preload 2.25-4.52 N·m (20-40 Lb-In)
thickness.
Ring Gear Backlash O. 13-0.23mm (0.005-0.009 Inch).
Assemble shim packs onto differential case hubs and No More Than 0.08mm (0.003
assemble new differential bearing cones. Continue to Inch) Variation in Any Three
assemble the axle assembly as described in this Places.
section.

SPECIFICATIONS
LUBRICANT CAPACITY
Tool Number/
Approximate Capacity Description Illustration
Imperial T50T-l00-A
~
Axle Model U.S. Pints Pints Liters Impact Slide Hammer
Dana 44 -IFS 3.6 3.0 1.7 TIOT·1GO-A
Dana 50 -IFS 3.8 3.2 1.8
T58L-l01-B
~
NOTE: Use Axle Lubricant F 1TZ-19580-A or equivalent Puller
meeting Ford specification WSL-M2C 191-A.
TUL·10'..
TORQUE SPECIFICATIONS T77F-ll02-A

Bearing Cup Puller
Bottom Ball Joint Nut 123-149 91-110
Top Ball Joint Nut 135 100
(Minimum) (Minimum)
End Yoke Nut 244-271 180-200 T77F-1102-A
Bearing Cap Bolts 108-122 80-90 T75L-1165-B

Differential Retaining Bolts 41-54 30-40 Axle Bearing / Seal Plate
Ring Gear Bolts (Grade 9) 95-122 70-90

(Model 44)
T75T-1176-A
Ring Gear Bolts (Grade 9) 129-142 95-105 Threaded Drawbar
(Model 50)
Support Arm Tabs to Carrier Bolts 135 100
Driveshaft to Yoke Nuts and 11-20 8-15 "IT-1171-A
U-Bolts
Coil Spring / Insulator to Lower 41-94 30-70 T83T-1244-A
Spring Seat - Needle Bearing Replacer
Upper Spring Retainer and Screw 18-24 13-18

Axle Assembly to Crossmember 163-203 120-150
Pivot Bolt
Shock Absorber Mounting Plate 116-162 86-120 TI3T·1244-A
U-Bolts
(Continued)
(Continued)
ALL RIGHTS RESERVED

(Continued)
Tool.Number / Tool Number/
Description illustration Description Illustration
T80T-3010-A T80T-4000-H
4WD Ball Joint Set Differential Axle Seal Replacer
e~gB
-A1 -A2 -AI ·A.
T80T·301 G-A TIOT-4OOO-H
T64P-3590-F T80T-4000-J
Pitman Arm Puller Differential Side Bearing
Replacer
TIOT-4OOO-J
T..'-3IIO·F T80T-4000-S
Spindle Bearing Replacer
T80T-4000-B
Differential Housing Spreader
Adapter
"IOT-4000-8
T80T-4000-8 T80T-4000-R
T80T-4000-0
TIOT..OOOoA
1801-4000-1
Seal Replacer
T80T-4000.0
T80T-4000-E
T80T-4000-W
Driver Handle
TIOT-4000-&
TIOT-4000-W
T80T-4000-F
Pinion Bearing Cup Replacer T80T-4020-A
Truck Pinion Depth Gauge
TIOT-4OOO-F
T83T-3132-A 1
Driver Handle
T83T-3132·A
T83T-4851-A
Companion Flange Replacer
TIOT-4020-A
T53T-4621-B
Pinion Bearing Cone Replacer
(Drive Pinion Bearing
(Continued) Installation - Model 44)
TI31-4121-8
(Continued)
ALL RIGHTS RESERVED

(Continued)
De8crlptlon IIIu8tration De8crlptlon IIIu8tration
T74P-4635-C T63P-9171-A
<
U-Joint Tool Keystone Clamp Pliers
T74P-tU1-C TUP-I171-A
T65L-4851-B T92T-4000-A
Companion Flange Remover Spindle Seal Replacer
T78P-4851-A
-~
Companion Flange Holding Tool TI2T-400G-A

Tool Number De8crlptlon
D80L-100-A Blind Hole Puller Set
T83T-4851-A D80L-630-5 Step Plate

Companion Flange Replacer D81T-3010-A Ball Joint Adapter Set
D81L-4000-A Driver Handle
D80T-4020-F44 Gauge Disc
TI3T-4IS1·A
D80T-4020-F47 Gauge Tube
T78P-5638-A
D78P-420 1-B Dial Indicator Magnetic Base
Suspension Bushing Service
Set D81L-4220-A Universal Bearing Remover
081 T-4222-BR Master Bearing Set
D81T-4222-C Master Bearing Set
081 T-4628-C Pinion Bearing Cup Remover Set
D81T-4628-D Pinion Bearing Cup Remover Set
0-34510-135 Master Bearing Set
TOOL-4000-E Differential Housing Spreader
T80T-5638-A
Front Suspension Bushing Tool
T57L-500-B
Bench Mounted Holding Fixture
(Continued)

ALL RIGHTS RESERVED
05-038-1 Axle, Front Drive, Dana Model 60 Monobeam 05-038-1
SECTION 05·038 Axle, Front Drive, Dana Model 60

Monobeam
VEHICLE APPLICATION ..•.....••..........•........•.••........•.05-038-1 DISASSEM8LY AND ASSEM8LY (Cont'd.)
DESCRIPTION AND OPERATION ..••...•......................05-038-1 Axle Shaft.•.....•...........•.....................................•05-038-31
DIAGNOSIS AND TESTING Depth Gauge Check•.....•....................................05-038-23
Axle, Front Drive....•...••.....•...••...•..........••.....•..•....05-038-1 Differential Case .....•.....•..•........•...•............•...••.05-038-19
REMOVAL AND INSTALLATION Gear Tooth Contact Pattern Check 05-038-28
Axle Shaft...•••..............••....•......•.............••...•.......05-038-2 Pinion 8earing Cup Installation .....................•....05-038-22
Axle, Front ...•.•...••........•.••...•......•.............••....•....05-038-8 Pinion 8earing Preload and Final Depth
Drive Pinion Oil Seal........••...••.....•.............••....•..05-038-12 Check .......•.•........•....•............•................•......05-038-23
Steering Knuckle and Upper and Lower 8all Pinion, Drive Gear and Differential Case
Joints ••.•••.•.•••.•.••.•..••••••••••••••...••••.•.•••••....•••..••.05-038-5 Carrier ..•.•..•.••••.•...•••.••..••...••..•••.••.•.•..•.••.••.•.••05-038-13
DISASSEM8LY AND ASSEM8LY SPECIFICATIONS .............•............•........•..............05-038-32
Assembly of Differential Into Housing ...•••..••......05-038-25 SPECIAL SERVICE TOOLS/EQUIPMENT ..........•.....05-038-32
Ring Gear and Pinion 8acklash .•••..•........•..•....05-038-25
VEHICLE APPLICATION
F-3504x4
Dana Model 60 monobeam front drive axle is used on

the F-350 4x4 vehicles and has open yoke design.
Other than the unique parts required for front-wheel
drive, these axles are mechanically identical to Model
60 rear axle assemblies (4006). It should be noted
that the automatic locking hubs are standard with
manual locking hubs optional. Refer to Section 05-03C
for description and operation of locking hubs.
Dana Model 60 Monobeam Front Drive Axle
DANA MODEL 80 MONOBEAM FRONT

DAIVE AXLE
E6532·B
Axle, Front Drive


ALL RIGHTS RESERVED
Axle Shaft Removal

1. Raise the front of the vehicle and install safety
SPECIAL SERVICE TOOL(S) REQUIRED stands.
Description Tool Number 2. Remove the lugnuts and remove the front wheel
Spindle Bearing Replacer T80T-4000-R (1007) and tire.
Spindle Seal Installer T92T-4000-A
Dana Model 60 Monobeam Front Drive Axle
E6533-E
Part Part
1 3220 Axle Shaft Assembly 8 1240 Wheel Bearing - Outer
2 1175 Rolling Diaphragm Seal 9 1197 Outer Locknut
3 3299 Integral Spacer / Seal 10 1B19~ Inner Locknut
4 3123 Caged Needle Bearing 11 1198 Lockwasher
5 4571 Nut 12 1243 Inner Bearing Cup
6 1102 Front Disc Brake Hub and 13 1244 Wheel Bearing - Inner
Rotor 14 1175 Grease Retainer
7 1239 Outer Bearing Cup 15 3105 Front Wheel Spindle'
(Continued)

caliper (28120) must be wired to the frame
or otherwise supported to prevent
suspending the disc brake caliper by the
flexible hose. If securing the disc brake
caliper is not practical, disconnect and plug
the hose to the disc brake caliper. Upon
installation, bleed the system as described in
Section 06-00.
Remove the disc brake caliper. Refer to Section
06-03 in the Body, Chassis Manual. Securely wire
the disc brake caliper to the frame.
4. Remove wheel hubs, bearings, and locknuts.
Refer to Section 05-03C.
5. Remove the front disc brake hub and rotor (1102)
from the front wheel spindle (3105).
E8787-A
6. Remove the nuts retaining the front wheel spindle
to the knuckle. Lightly tap the front wheel spindle
with a rawhide hammer to remove from the
knuckle.

ALL RIGHTS RESERVED
E8788·A
7. Remove the front disc brake rotor shield (2K004)

from the knuckle.
8. Pull the axle shaft assembly out of the steering
knuckle.
E6536-C
Part
1 D80L-100-T Collet (1-1 /4 to 1-1 /2 Inch)
2 D80L-l00-W Bridge Assembly
3 D80L-100-H Actuator Pin
4 3123 Bearing
Installation
9. NOTE: Actuator pin may travel far enough up and 1. NOTE: Replacement spindle bearings are
contact bridge. If this occurs, remove bridge and shipped with a corrosion preventive gel. This is
use a slide hammer to complete removal. not a lubricant. Bearing must be cleaned and
repacked with the specified greased.
If required, remove the caged needle bearing
seal, and integral thrust washer from the front If removed, pack a new bearing with High
wheel spindle. Pull the bearing out of the front Temperature 4x4 Front Axle and Wheel Bearing
wheel spindle using Collet (1-1 / 2 to 1-3/ 4 inch) Grease E8TZ-19590-A or equivalent meeting
D80l-100-T, Actuator Pin D80l-100-H and Ford specification ESA-M1C198-A.
Bridge Assembly D80l-1 OO-W or equivalents. 2. NOTE: The writing on the bearing must face the
inboard side of the front wheel spindle, toward
the driving tool.
Position the bearing in the bore of the front wheel
spindle.

ALL RIGHTS RESERVED
3. Drive the bearing in the front wheel spindle with 6. CAUTION: Do not bend the sheet metal
Spindle Bearing Replacer TBOT-4000-R and portion of the seal.
Driver Handle TBOT-4000-W until the tool Install the rolling diaphragm seal on the axle
bottoms out against the front wheel spindle. shaft. Seat the rolling diaphragm seal by lightly
tapping on the inner sheet metal lip of the seal
with a seal installer, Driver Handle
TB3T-3132-A 1, and a hammer to make sure that
it is seated squarely.
AXLE SHAFT
3219
E6537·B
4. Install the thrust washer / seal assembly using

T92T-4000-A.
E9786-A
7. Lightly coat the thrust face of the lips of the seal

bore of the front wheel spindle and the rolling
DRIVER diaphragm seal on the axle shaft with High
HANDLE Temperature 4x4 Front Axle and Wheel Bearing
TBOT-4000-W Grease EBTZ-19590-A or equivalent meeting
Ford specification ESA-M 1C 19B-A.
SPINDLE SEAL
REPLACER
T92T-4000-A
FRONT WHEEL
SPINDLE
3105
E9787-A E7137-B
5. Lightly coat the thrust face of the seal in the bore

of the axle shaft and the rolling diaphragm seal
lips on the axle shaft with High Temperature 4x4
Front Axle and Wheel Bearing Grease
EBTZ-19590-A or equivalent meeting Ford
specification ESA-M 1C 19B-A.
ALL RIGHTS RESERVED
8. Carefully guide the axle shaft through knuckle Steering Knuckle and Upper and Lower Ball
and into the axle housing. Check that the splines Joints
of the axle shaft are engaged in the differential
side gear splines. SPECIAL SERVICE TOOL(S) REQUIRED

U-Joint Tool T74P-4635-C
Ball Joint Remover / Replacer T92T-3010-A
Ball Joint Remover / Replacer T92T-30 10-8
Removal
1. NOTE: If replacing both or just the front
suspension upper ball joint (3049), the front
suspension lower arm ball joint (3050) must be
removed first and installed last.
Raise the vehicle on a hoist and position suitable
safety stands under the frame.
2. Remove the wheel hub bolts (1107) and the
wheel (1007) and tire.
9. Install the front disc brake rotor shield on the
3. Remove the disc brake caliper (2B 120) as
steering knuckle.
described in Section 06-03. Securely wire the
10. Place front wheel spindle on steering knuckle. disc brake caliper to the frame.
Install nuts and tighten to 68-81 N·m (50-60 Ib-ft).
4. Remove the axle shaft and front wheel spindle
(3105) as described under Axle Shaft Removal
and Installation in this section.
5. Disconnect the steering arm from the knuckle.
6. Remove the cotter pin from the stud of the front
suspension upper ball joint. Loosen retaining nuts
of both the front suspension upper ball joint and
the front suspension lower arm ball joint. Remove
the top nut.
11. Install the front disc brake hub and rotor on the
front wheel spindle, inspecting the wheel bearings
and grease seal, and making sure there is
adequate lubrication with High Temperature 4x4
Front Axle and Wheel Bearing Grease
specification ESA-M 1C 198-A.
12. Install bearing, locknuts, and hub locks. Refer to
Section 05-03C.
13. Install the disc brake caliper as described in
Section 06-03.
14. Install the front wheel and tire. Install the wheel E8791·A
hub bolts (1107) and tighten to specification.

ALL RIGHTS RESERVED
7. Using a rawhide or heavy-duty plastic hammer,

hit sharply on the top stud to free the knuckle
from the tube yoke. After the knuckle is free from
the yoke, remove the lower nut and remove the
knuckle from the tube yoke.
E8794-A
10. Assemble U-Joint Tool T74P-4635-C, Ball Joint

Remover / Replacer 081 T-30 10-A4 and Ball Joint
Remover / Replacer 081 T-30 10-A3 or
equivalents over the front suspension upper ball
E8792-A joint. Turn the forcing screw clockwise to remove
the front suspension upper ball joint.
8. Secure the knuckle in a vise. Remove the snap
ring from the front suspension lower arm ball joint.
BALL JOINT
REMOVER/REPLACER STEERING
D81T-301 0-A4 KNUCKLE
AND A3
E8795-B
E8793·A
9. Assemble U-Joint Tool T74P-4635-C and Ball

Joint Remover / Replacer T92T-30 1O-A over the
front suspension lower arm ball joint. Turn the
forcing screw clockwise to remove the front
suspension lower arm ball joint.

ALL RIGHTS RESERVED
Installation
1. NOTE: The front suspension upper ball joint must
be installed first.
Position the front suspension upper ball joint
along with U-Joint Tool T74P-4635-C, Receiver
Cup 081T-3010-A5, Ball Joint
Remover / Replacer Tools 081 T-30 1O-A 1,
081T-3010-A3 and 081T-3010-A4 or
equivalents on the knuckle. Turn the forcing
screw clockwise until the front suspension upper
ball joint bottoms in the bore. Remove the tools.
BALL JOINT
REMOVER/REPLACER STEERING
(INSIDE)-D81T-3010-A1 KNUCKLE
REMOVER/REPLACER
(MJDDLE)-D81T-301o-A3
REMOVER/REPLACER
(OUTSIDE)-D81T-3010-A4
E8799·B
BALL JOINT
REMOVER/REPLACER
(OUTSIDE) BALL JOINT
D81T-3010-A4 REMOVER/REPLACER
(INSIDE)
D81T-3010-A1
E8797-e
2. Position the front suspension lower arm ball joint

and U-Joint Tool T74P-4635-C, Ball Joint
Remover / Replacer T92T-30 1O-B and Ball Joint
Remover / Replacer T92T-30 1O-A on the knuckle.
Turn the forcing screw clockwise until the front
suspension lower arm ball joint bottoms in the
bore. Remove the tools.
C-FRAME
E88OO-C
ALL RIGHTS RESERVED
05-03B-8 Axle, Front Drive, Dana Model 60 Monobeam 05-038-8
3. Install the snap ring on the front suspension lower 8. Install the disc brake caliper. Refer to Section
arm ball joint. 06-03 in the Body, Chassis Manual.
9. Connect the steering arm to the knuckle. Tighten
the attaching nut to 95-135 N·m (70-100 Ib-ft).
10. Install the tire and wheel. Tighten the wheel hub
bolt to specifications. Refer to Section 04-04 in
11. Remove the safety stands and lower the vehicle.
Axle, Front
Pitman Arm Puller T64P-3590-F
Removal
1. Raise the vehicle on a twin-post hoist.
2. Remove the front wheels (1007) and tires from
E8793-A the vehicle.
caliper (28120) must be wired to the spring
4. Assemble the knuckle to the tube yoke. Install the or otherwise supported to prevent
camber bushing, if previously removed. Install the suspending the disc brake caliper by the
attaching nut of the front suspension upper ball flexible hose. Allowing the disc brake caliper
joint. Do not tighten at this time. to hang by the flexible hose could result in
5. Install the attaching nut of the front suspension brake line failure. If suspension of the disc
lower arm ball joint. brake caliper is not practical, remove It.
Refer to Section 06-03 in the Body, Chassis
6. CAUTION: If these tightening procedures are Manual.
not followed, life of the front suspension
upper ball Joint and front suspension lower Remove the disc brake caliper from the spindle.
arm ball Joint will be reduced. Refer to Section 06-03 in the Body, Chassis
Manual. .
Tighten both attaching nuts as follows:
4. Remove the washers and nuts securing the front
a. Tighten nuf of the front suspension lower arm stabilizer bar links (5K483) to the front stabilizer
ball joint to 47 N·m (35Ib-ft). bar (5482). Disconnect the front stabilizer bar
b. lighten nut of the front suspension upper ball links from the front stabilizer bar.
joint to 95 N·m (70 Ib-ft). 5. If required, remove the U-bolts and bolts and nuts
c. Advance nut of the front suspension upper retaining the front stabilizer bar and stabilizer bar
ball joint to next castellation, and install new brackets (5486) to the axle and remove the front
cotter pin. stabilizer bar.
d. Retighten nut of the front suspension lower
arm ball joint to 203 N·m (150 Ib-ft).
7. Assemble the front wheel spindle and axle shaft.
Refer to Axle Shaft Removal and Installation in
this section.

ALL RIGHTS RESERVED
Front Stabilizer Bar Assembly
Part Part
1 5K483 Front Stabilizer Bar Link 3 5486 Stabilizer Bar Bracket
2 5482 Front Stabilizer Bar 4 N606088-S Bolt
(Continued) 5 5455 U-Bolt
6. Remove the cotter pins and castellated nuts

securing the connecting rod of the front wheel
spindle (3105) to the steering knuckles. Separate
the connecting rods from the steering knuckles
using Pitman Arm Puller T64P-3590-F. Wire the
steering linkage to the spring.
Spindle Connecting Rod Attachment Locations
E1337-C
7. Remove the two nuts and U-bolts from the front

driveshaft U-joint flange.

ALL RIGHTS RESERVED
05-03B-10 Axle, Front Drive, Dana Model 60 Monobeam 05-03B-10
8. NOTE: Mark yoke and driveshaft with a marking 9. Disconnect the vent tube at the axle housing. Plug
paint pen for assembly in the same position. the vent fitting.
Disconnect the driveshaft from the front axle
pinion flange. Securely wire the driveshaft to the
frame.
10. On the right-hand side of the vehicle, remove the

nut and bolt, and disconnect the tracking bar from
the right-hand spring cap.
El3ll-1A .
Tracking Bar
SPRING
CAP
TRACKING
BAR NUT AND
BOLT E6340-2A
11. Carefully lower the twin-post hoist until the vehicle 12. WARNING: BEFORE PROCEEDING, MAKE
is approximately three feet from the floor. SURE THAT THE VEHICLE IS SECURELY
SUPPORTED.
Position safety stands on the front springs about
halfway between the front axle and the rear
mounting shackle. Lower the vehicle so the front
springs rest on the safety stands.

ALL RIGHTS RESERVED
13. Support the axle under the differential carrier with

a suitable jack, such as Rotunda Tool 077-00008
or equivalent.
14. Remove the U-bolts and nuts securing the axle to
the spring.
15. Carefully lower the axle from the vehicle.
16. If required, place the axle in a suitable differential
carrier repair stand.
U-BOLTS E6342-C
Installation
1. With the axle supported under the differential
carrier by a suitable transmission jack, carefully
raise the axle to the vehicle. Make sure that the
retaining bolt head protruding from the leaf spring E6343-C
plate seats in the recessed portion of the axle
spring mounting plate.
2. Install the nuts, U-bolts and spring caps securing Part
the axle to the front spring. Tighten to 113-153 Item Number Description
N·m (83-113Ib-ft). 1 N801485-S56 Bolt
3. Remove jacks and raise the vehicle to a suitable 2 5A500 Spacer
working height. Remove safety stands. 3 N801342-S2 Nut
4 5310 Spring
(83-113 Lb-Ft)
4. Connect the driveshaft to the front axle pinion

flange, secure with nuts and U-bolts and tighten to
31-40 N·m (23-30 Ib-ft). Refer to Section 05-01.
5. On the right-hand side of the vehicle, connect the
tracking bar to the spring cap, secure with nut
and bolt. Tighten to 70-100 N·m (52-74Ib-ft).
6. Connect the vent tube to the axle housing.
7. Connect the connecting rods of the front wheel
spindle to the steering knuckles. Secure the
connecting rod ends with castellated nuts.
Tighten to specifications listed at the end of this
section. Install cotter pins. If necessary, advance
nut to next castellation to install cotter pin.
8. Connect front stabilizer bar link to front stabilizer
bar. Tighten to 21-33 N·m (15-24Ib-ft).
1995 F-150, F-250, F-350, Bronco, F-S·uper Duty Powertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
05·038·12 Axle, Front Drive, Dana Model 60 Monobeam 05·038·12
9. If removed, position front stabilizer bar and Drive Pinion Oil Seal
stabilizer bar bracket on axle shaft housing and
tighten to specifications listed at the end of this SPECIAL SERVICE TOOL(S) REQUIRED
section.
Companion Flange Remover T65L-4851-B
Removal
1. NOTE: The pinion seal can be replaced without
removing the axle from the vehicle. Compounded
or synthetic rubber seals do not require soaking.
Raise the vehicle on a hoist or raise the front end
of the vehicle with a jack. Install safety stands
under the frame rails and lower the jack or hoist
far enough to allow the axle to drop into the
rebound position for working clearance.
2. Mark U-joint flange and driveshaft prior to
removing. Remove the nuts and two U-bolts from
the front axle U-joint flange and disconnect the
driveshaft from the front axle pinion flange. Wire
the driveshaft to the frame.
3. Using Companion Flange Holding Tool
T57T-4851-B to hold the pinion companion
flange, remove the pinion shaft nut.
4. Using Companion Flange Remover Tool
T65L-4851-B remove the companion flange.
5. Using Seal Remover TOOL-1175-AC or
equivalent in combination with Slide Hammer
T50T-100-A remove the pinion seal.
Installation
1. Clean the seat of the pinion seal. Drive the pinion
seal into the housing using Pinion Seal Replacer
T83T-4676-A. Coat the seal lip of the new seal
E8344-B with a small amount of Premium Rear Axle
Lubricant C6AZ-19580-E or equivalent meeting
Ford specification ESW-M2C 105-A. Do not put
Part sealer on the sealing lip.
2. Coat the inside of the pinion flange with a small
1 5K483 Front Stabilizer Bar Link quantity of Premium Rear Axle Lubricant
2 5493 Lower Suspension Arm C6AZ-19580-E or equivalent meeting Ford
Stabilizer Bar Insulator specification ESW-M2C105-A and install the
3 5486 Stabilizer Bar Bracket flange on the pinion shaft using Companion
4 5482 Front Stabilizer Bar Flange Replacer TOOL-4858-E or equivalent.
5 5455 U-Bolt (RH) 3. Install a new pinion attaching nut on the pinion
6 3002 Axle Shaft Housing shaft. Tighten to specifications listed at the end of
7 5484 Rack and Pinion Mounting this section.
Bracket Insulator
4. Connect the driveshaft to the front axle pinion
8 18171 Washers
flange and align marks made prior to removal.
9 N805537-S 100 Bolt and Retainer
Secure with nuts and U-bolts and tighten to
10. Install disc brake calipers and part of front disc specifications listed at the end of this section.
brake hub and rotors (1102). Refer to Section 5. Raise the vehicle, remove the safety stands and
06-03. then lower the vehicle to road position. Check the
11. Install the wheel and tire on the vehicle. level of axle lubricant and add the specified
lubricant as necessary.
12. Lower the vehicle to the ground.

ALL RIGHTS RESERVED
05·038·13 Axle, Front Drive, Dana Model 60 Monobeam 05-038-13
Pinion, Drive Gear and Differential Case 2. Remove the axle shafts. Refer to Axle Shaft
Carrier Removal and Installation in this section.
3. Position suitable container under differential
SPECIAL SERVICE TOOL(S) REQUIRED carrier. Remove axle housing cover (4033) and
drain lubricant from axle. The lubricant will drain
Description Tool Number out as the axle housing cover is removed. Tip
Impact Slide Hammer T50T-100-A carrier to allow lubricant to drain completely.
Companion Flange Holding Tool T57T-4851-B 4. Remove any residual gasket material from carrier
Companion Flange Remover T65L-4851-B mating surface. Also clean cover face of carrier,
Bearing Cup Puller T77F-1102-A making sure it is free of any nicks or burrs.
Jet Plug Remover T77L-9533-B
5. NOTE: Mating letters are stamped on bearing
caps and carrier. Letters are in vertical and
Disassembly horizontal positions. Note the letter positions
1. Remove the front axle from the vehicle. Refer to before removal. At time of assembly they are to
Axle, Front, Removal and Installation in this be assembled exactly as removed.
section. Loosen capscrews and remove bearing caps.
Differential Assembly
Part Part
1 - Bearing Cap (Part of 3010) 10 4616 Differential Drive Pinion
2 4222 Differential Bearing Cup Bearing Cup
3 4211 Differential Pinion Shaft 11 4670 Baffle
4 4228 Differential Side Gear Thrust 12 372632-S Washer
Washer 13 354845-38 Nut
5 4236 Differential Side Gear 14 4851 Companion Flange
6 4215 Differential Side Gear 15 4859 Drive Pinion Oil Seal
7 4230 Differential Pinion Thrust Deflector
Washer 16 4676 Rear Axle Drive Pinion Seal
8 - Carrier (Part of 3010) 17 4621 . Differential Pinion Bearing
9 4672 Preload Shims 18 4670 Oil Slinger
(Continued) 19 3254 Axle Shaft Oil Seal
(Continued)

ALL RIGHTS RESERVED
Part Part
20 4109 Drive Pinion Shim 23 1244 Differential Bearing
21 3222 Ring Gear and Pinion 24 4033 Axle Housing Cover
22 4241 Roll Pin 25 4067 Differential Bearing Shim
(Continued) 26 853051-S Fill Plug
6. Place Differential Housing Spreader

TOOL-4000-E or equivalent on the differential
case (4204). Install Dial Indicator D78P-4201-B
or equivalent on the carrier housing. Do not
spread housing more than 0.38mm (0.015 inch).
o .. A
MATING LETTERS ~
DIAL INDICATOR
D78P-4201-B
292cnm
(11.50 INCH)
SPREADER HOLE TO SPREADER HOLE
Ea33-1C

ALL RIGHTS RESERVED
7. NOTE: Use caution to avoid damage to ring gear 10. Place a few shop towels over the vise to prevent
and drive pinion. the ring gear teeth from being nicked when it falls
Pry differential case from carrier with two pry from the differential carrier.
bars. After differential case has been removed, 11. NOTE: Whenever removing the ring gear bolts,
remove spreader. Mark or tag bearing cups for always replace with new bolts upon assembly.
correct positioning during assembly. Place differential case in vise. Remove bolts. Tap
ring gear with a rawhide hammer to free it from
the differential case. Remove differential case
and ring gear from vise.
8. Remove differential bearings with Pinion and

Carrier Bearing Puller 081 L-4220-A or
equivalent. Place tool in a vise when removing
bearing. Wire differential bearing shims (4067), 12. Replace differential case in vise and use a small
differential bearing cup (4222) and bearing cone drift to drive out the roll pin that secures the
together. Identify from which side they were differential pinion shaft (4211).
removed. (Ring gear side or opposite side.) If
differential bearing shims are damaged, replace
during assembly.
9. Reposition differential case in puller and remove
other bearing cone as described above. Replace
bearings whenever they are removed from the
carrier.
PINION AND CARRIER

BEARING PULLER
081 L-4220-A
E8671-B
E4846-B

ALL RIGHTS RESERVED
DISASSEMBLY AND ASSEMBLY (ColJtinued)
13. Remove differential pinion shaft with drift. 18. Turn nose of carrier in a horizontal position,
remove pinion nut. Hold end yoke or flange with
Companion Flange Holding Jool T57T-4851-8
DIFFERENTIAL and remove pinion nut and washer: .
PINION SHAFT
4211 19. Remove end yoke or flange with Companion
Flange Remover T65L-4851 ..8. If end yoke or
flange shows wear in the area of the seal contact,
replace.
NOTE: Service kit has 10 drive pinion shims of various
thicknesses.
NOTE: On the spline end of the pinion there are drive
pinion shims. These shims may stick to the pinion (part
of ring gear) or bearing or even fall out. These drive
pinion shims are to be collected and kept together
since they will be used later in assembly. Try not to
damage drive pinion shims. If drive pinion shims are
damaged, replace with new ones. Drive pinion shims
E6872-B
are available in'the following thicknesses.
14. To remove differential side gears (4236) and PINION PRELOAD SHIMS
pinion gears, rotate the differential side gears. Available Thicknesses
This will allow the differential pinion gears (4215)
to turn to the opening of the case. mm In.
.36 .014
15. Remove pinion gears and the differential pinion
thrust washer (4230) behind the pinion gears. .41 .016
16. Lift out differential side gears and differential side .46 .018
gear thrust washers (4228). .51 .020
17. NOTE: If excessive wear is visible on all parts, it .56 .022
is suggested that the complete differential be .76 .030
replaced. If anyone of the gears are to be
.38 .015
replaced, REPLACE AS A SET.
.53 .021
Inspect all parts, including the machined surfaces
of the differential case itself. .58 .023
.25 .010
20. Remove pinion by tapping with a rawhide

hammer. Catch the pinion with your hand to
prevent it from falling to the ground and being
damaged.
DIFFERENTIAL
SIDE GEAR
4~36
E6347·B

ALL RIGHTS RESERVED
21. Pull out pinion seal with Bearing Cup Puller 23. Remove the inner bearing cup with Pinion Bearing
T77F-1102-A and Impact Slide Hammer Cup Remover D81 T-4628-A and Driver Handle
T50T-100-A. Discard pinion seal. REPLACE D81 L-4000-A or equivalents.
WITH NEW pinion seal AT TIME OF ASSEMBLY.
Remove differential pinion bearing (4621) and Bearing Cup Removal
outer oil slinger.
SLIDE HAMMER
T50T-100-A
PINION
SEAL
4676
OUTER CUP REMOVAL
E4834-C
22. CAUTION: Do not nick carrier bore.

NOTE: The inner carrier section may vary in
pinion bore depth due to the possibility of the
need for either a baffle or oil slinger or both.
NOTE: Shims are located between the bearing
cup and carrier bore and may also include a oil
slinger. If shims and oil slingers are bent or
nicked, replace at time of assembly. Wire shim INNER DIFFERENTIAL PINION
stacks together and measure each. If stack has BEARING CUP REMOVAL E6349-D
to be replaced, replace with same thickness.
NOTE: Both baffle and oil slinger are part of the Part
drive pinion shims and are to be kept intact for Item Number Description
assembly.
1 D81T-4628-A Pinion Bearing Cup Remover
NOTE: The baffle serves the same purpose as a -Inner
dam, to ensure the differential pinion bearings are 2 081 T-4628-0 Pinion Bearing Cup Remover
maintained with lubricant. The slinger serves the - Outer
purpose of assisting the lubricant to flow up 3 081 L-4000-A Driver Handle
through the oil channels to lubricate the 4 4616 Differential Drive Pinion
differential pinion bearings. If used, they are part Bearing Cup
of the pinion setting adjustment.
Turn nose of carrier down. Remove outer
differential drive pinion bearing cup (4616) with
Pinion Bearing Cup Remover 081 T-4628-0 and
Driver Handle 081 L-4000-A or their equivalents.
Locate driver on back edge of differential drive
pinion bearing cup; drive differential drive pinion
bearing cup out of carrier.

ALL RIGHTS RESERVED
REAR AXLE
DRIVE PINION SHAFT
OIL SLINGER
4670 OIL
BAFFLE
E7115-C
24. Remove differential pinion bearings from pinion

with Pinion and Carrier Bearing Puller
D81L-422Q-A or equivalent. Bend the slinger as
required to obtain clearance for remover tool 25. If required, remove the inner axle s~aft oil seals
installation. Discard the slinger. (3254) with Jet Plug Remover T77L-9533-B.
Thread the remover tool into the axle shaft oil
seal, remove and discard axle shaft oil seal.
Thread the remover tool into the metallic seal
housing, remove and discard seal housing.
Inner Axle Shaft Seal Removal
AXLE SHAFT OIL SEAL REMOVAL SEAL METAL HOUSING REMOVAL

SEAL METAL
HOUSING
~(
JET PLUG PULLER
T77L-9533-B
~ JET PLUG PULLER
T77L-9533-B
~
E. . . .

ALL RIGHTS RESERVED
Differential Case
Assembly
DRIFT
DIFFERENTIAL
1. NOTE: An easy way to assemble the differential PINION SHAFT
side gears and pinion gears is to have all parts 4211
lubricated before assembly.
Place differential case (4204) in vise. Apply High
Lubricant E8TZ-19590-A or equivalent meeting
Ford specification ESA-M1C198-A, to new
differential side gear thrust washers (4228) and
to hubs and thrust face of the new differential side
gears.
2. Assemble both differential side gears. Apply
grease to differential pinion thrust washers
(4230) and new pinion gears. Assemble new
differential pinion gears (4215) and differential E6401-B
pinion thrust washers.
7. Assemble roll pin. Peen metal of differential case
3. Assemble both differential side gears and over roll pin to lock in two places 180 degrees
differential side gear thrust washers, hold in place
apart.
with hand, then assemble the pinion gears and
differential pinion thrust washers to hold the
differential side gears in place.
4. Rotate the differential side gears until the holes of
the differential side gear thrust washers and
pinion gears line up with the holes of the
differential case. If the differential side gears
cannot be rotated by hand, install one of the axle
shafts into the spline of the differential side gear
and use a pipe wrench to turn the shaft.
ROLL PIN
4241
PEEN
90 DEGREES
EITHER SIDE
FROM SLOT IN
ROll PIN
PIN
E6402-D
8. Make sure flange face of the differential case is

PINION GEAR
4215 free of nicks or burrs. Assemble ring gear to
differential case. Line up holes of the ring gear
E6350-B with those of the differential case. Use new ring
gear bolts. Draw up bolts alternately and evenly.
5. Use a drift to line up the holes with those of the Tighten grade 8 ring gear bolts to 136-162 N·m
differential case. (100-120 Ib-ft). Tighten grade 9 ring gear bolts to
6. Assemble differential pinion shaft (4211), drive on 169-183 N·m (125-135Ib-ft).
differential pinion shaft to remove drift. Align hole
of the roll pin of the differential pinion shaft with
the hole of the roll pin of the differential case.

ALL RIGHTS RESERVED
9. Place the inner axle shaft oil seals (3254) in the

axle tube housing. Press both axle shaft oil seals
in at the same time with an appropriate
installation tool. Make sure axle shaft oil seals are
pressed in straight and not cocked in the bore.
Coat the lips of the axle shaft oil seals with High
Lubricant E8TZ-19590-A or equivalent meeting
Ford specification ESA-M1C198-A.
10. Install Master Differential Bearings Tool
081 T-4222-D or equivalent onto differential case.
Remove all nicks, burrs, dirt, etc., from hubs to
allow bearings to rotate freely.
E711..,B
~
13. Force the differential as far as it will go in the

opposite direction. Repeat these steps until you
have obtained the same reading. Record the
reading of the indicator. This will be the total
amount of differential bearing shims (4067)
11. NOTE: Dial indicator should have a minimum required (less preload) and will be calculated later
travel capability of 5.08mm (0.200 inch). during assembly.
Assemble differential case into carrier (less 14. NOTE: Ring gears and pinions are supplied in
pinion). Mount Dial Indicator with Bracketry matched sets only. Matching numbers are etched
TOOL-4201-C or equivalent as shown. Locate tip on both the pinion and ring gear for verification. If
of indicator on flat surface of one of the ring gear a new gear set is being used, verify the numbers
bolt spot faces. of each pinion and ring gear before proceeding
12. Force differential (4026) as far as possible with assembly.
toward the indicator. With force still applied, set After making sure the readings are correct,
indicator at zero. remove indicator and differential from housing. Do
not remove master bearings from differential case
at this time.

ALL RIGHTS RESERVED
15. The reading obtained in Step 13 is the total On the button of each pinion, there is etched a
differential case end play which will be needed in plus (+ ) number, a minus (-) number, or a zero (0)
Assembly of Differential into Housing in this number which indicates the best running position
section. for each particular gear set. This dimension is
controlled by the shimming behind the inner pinion
bearing cup.
NOTE: Do not use the button of the pinion for pinion
positioning. The button of the pinion is no longer a
ground surface.
For example, if a pinion is etched a plus m+8 (+3),
this pinion would require 0.08mm (0.003 inch) less
DIAL INDICATOR shims than a pinion etched •'0". This means by
WITH BRACKETRY
TOOL-4201-C
removing shims, the mounting distance of the pinion is
increased, which is what m+8 (+3) indicates. Or if a
pinion is etched m-8 (-3), we would want to add
0.08mm (0.003 inch) more shims than would be
required if the pinion were etched "0". By adding
0.08mm (0.003 inch) shims, the mounting distance of
the pinion was decreased, which is what m-8 (-3)
indicated.
If the old gear set is to be reused, measure the old
shim pack and build a new shim pack to this same
dimension. If a baffle and oil slinger is used in the axle,
it is considered as part of the shim pack.
To change the pinion adjustment, shims are available
E6403-e in thicknesses of 0.08,0.13 and 0.25mm (0.003,
0.005 and 0.010 inch).
NOTE: If baffle or oil slinger is bent or mutilated, it
BunON END (MAY NOT
BE A GROUND SURFACE) DIFFERENTIAL
should be replaced.
RING GEAR Measure each shim separately with a micrometer and
AND PINION
3222 add together to get the total shim pack thickness from
the original buildup.
If a new gear set is being used, notice the (+ ) or (-)
etching on both the old and new pinion and adjust the
thickness of the new shim pack to compensate for the
difference of these two figures.
For example, if the old pinion reads m+5 (+ 2) and the
new pinion is m-5 (-2), add 0.10mm (0.004 inch) shims
to the original shim pack.
STANDARD PINION E7117-E
The distance from the centerline of the ring gear

to the backface of the pinion is 127mm (5.000
inch).
New Pinion Marking (English)

Old Pinion
Marking -4 ·3 -2 -1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003
0 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004
-1 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005
-2 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006
-3 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007
-4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008

ALL RIGHTS RESERVED

Old Pinion
Marking -10 -8 -5 -3 0 +3 +5 +8 +10
+10 +.20 +.18 +.15 +.13 +.10 +.08,' +.05 +.03 0
+8 +.18 +.15 +.13 +.10 +.08 +.05 +.03 0 -.03
+5 +.15 +.13 +.10 +.08 +.05 +.03 0 -.03 -.05
+3 +.13 +.10 +.08 +.05 +.03 0 -.03 -.05 -.08
0 +.10 +.08 +.05 +.03 0 -.03 -.05 -.08 -.10
-3 +.08 +.05 +.03 0 -.03 -.05 -.08 -.10 -.13
-5 +.05 +.03 0 -.03 -.05 -.08 -.10 -.13 -.15
-8 +.03 0 -.03 -.05 -.08 -.10 -.13 -.15 -.18
-10 0 -.03 -.05 -.08 -.10 -.13 -.15 -.18 -.20
Pinion Bearing Cup Installation 3. Place the Inner Bearing Cup Replacer Tool
T56T-4616-B2 on the inner differential drive
SPECIAL SERVICE TOOL(S) REQUIRED pinion bearing cup.
Description Tool Number 4. Place the Outer Bearing Cup Replacer Tool
T56T-4616-B 1 on the outer differential drive
Pinion Bearing Cup Replacer T56T-4616-B pinion bearing cup.
5. Install the Threaded Drawbar T75T-1176-A into
1. Place the preload shims and oil slinger, if the replacer tools. Tighten the drawbar to install
required, under the inner differential drive pinion the differential drive pinion bearing cups into the
bearing cup (4616) as shown. carrier bore.
2. Place the inner and outer differential drive pinion
bearing cups into the carrier bore.
Pinion Bearing Cup Installation
E84CM-C
"
Part Part
1 T56T-4616-B2 Inner Bearing Cup Replacer 5 T75T-1176-A Drawbar
2 T56T-446-B 1 Outer Bearing Cup Replacer 6 4616 Differential Drive Pinion
3 - Inner Cup Installation View Bearing Cup (Outer)
4 - Outer Cup Installation View 7 4616 Differential Drive Pinion
Bearing Cup (Inner)
(Continued)

ALL RIGHTS RESERVED
Depth Gauge Check

Part
SPECIAL SERVICE TOOL(S) REQUIRED Item Number Description
Description Tool Number (Outer)
Pinion Depth Gauge T79P-4020-A 4 T76P-4020-A 11 Handle
Gauge Block T80T-4020-F42 5 4621 Differential Pinion Bearing
Screw T80T-4020-F43 (Inner)
Pinion Seal Replacer T56T-4676-B 6 T80T-4020-F43 Screw
Axle Bearing / Seal Plate T75L-1165-B 7 T76P-4020-A3 Aligning Adapter
Axle Bearing / Seal Replacer T75L-1165-DA 8 D80T-4020-F48 Gauge Tube
Companion Flange Replacer T85T-4851-AH
1. NOTE: If any of the gauge surfaces become

nicked, the high spots must be removed with a Pinion Bearing Preload and Final Depth
medium India oilstone to ensure correct readings.
Check
Place a new inner differential pinion bearing
1. Assemble oil slinger (if used) onto pinion.
(4621) over the proper aligning adapter and
Assemble differential pinion bearing (4621) using
insert into the differential pinion bearing retainer.
Axle Bearing / Seal Plate T75L-1165-B and Axle
Place the outer differential pinion bearing (new or
Bearing/Seal Replacer T75L-1165-DA.
used if in good condition) into the differential drive
pinion bearing cup (4616) and assemble the
handle onto the screw and hand-tighten. Note the
3/8 inch square drive in the handle to be used for
obtaining the proper differential pinion bearing
preload. Tighten to preload of 2.26-4.51 N·m
(20-40Ib-in).
pinion bearing bore. Install the bearing caps and
tighten capscrews to 109-122 N·m (80-90 Ib-ft).
3. NOTE: The feeler gauge fit between the gauge
tube and the gauge block should be a slight
drag-type feeling. Make sure shims or feeler
gauges are free of dirt to insure a correct reading.
Using a feeler gauge tool or shims, select the
thickest feeler shim that will enter between the
gauge tube and the gauge block. Insert the feeler
gauge directly along the gauge block to ensure a
correct reading.
E6853-e
Part
2 T78P-4020-A 15 Gauge Disc
(Continued)

ALL RIGHTS RESERVED
2. Assemble outer differential pinion bearing, oil 6. If rotating torque is within specifications, remove
slinger and pinion seal into housing. Coat the nut and install new pinion nut and tighten to
pinion seal with grease. Install the pinion seal with specifications listed at the end of this section.
Pinion Seal Replacer T56T-4676-B. After
installation, make sure the garter spring did not
pop out. If the garter spring pops out, remove and
replace pinion seal.
The illustration shows the arrow in the pinion

pointing in two directions.
• The arrow pointing toward the end yoke
indicates by removing drive pinion shims, the
distance from the centerline of the axle to the
pinion mounting surface (back face of pinion) is
increased giving a plus reading.
• The arrow pointing toward the drive pinion
indicates by adding pinion shims, the distance
from the centerline of the axle to the pinion
3. Assemble drive pinion shims onto pinion and button is decreased, giving a minus reading.
install housing.
• The pinion bearing preload shim pack does not
4. Assemble end yoke, washer and old pinion nut. affect the pinion depth setting.
Tighten nut to specifications listed at the end of
this section. • However, drive pinion shim change will affect
pinion preload. If position of pinion is changed,
5. Using an N·m (Ib-in) torque wrench, rotate pinion. the preload shim pack must be changed in the
The torque required to rotate the pinion should be same amount in order not to change preload.
between 2.26-4.51 N·m (20-40 Ib-in). To increase
preload, remove drive pinion shims from pinion.
To decrease preload, add drive pinion shims to
pinion.

ALL RIGHTS RESERVED
• The arrows on the ring gear show the method 8. Install the washer and nut and tighten nut to
for increasing or decreasing ring gear backlash torque specification listed at the end of this
by inserting or removing differential bearing section.
shims (4067).
~
REMOVE SHIMS COMPANION FLANGE
REPLACER
T85T-4851-AH
INCREAS=--E......_ .
SH
1 E6406-F
E4852·18
Part
Item Number Description Assembly of Differential Into Housing
(Inner) Ring Gear and Pinion Backlash
2 4621 Differential Pinion Bearing 1. Place differential (4026) into housing. Differential
(Outer) master bearings should still be assembled to
3 4672 Pinion Bearing Shim differential case (4204).
4 4109 Drive Pinion Shim
7. Install the yoke with Companion Flange Replacer

T85T-4851-AH if necessary to draw the drive
pinion up to engage the nut.

ALL RIGHTS RESERVED
2. Set up Dial Indicator with Bracketry 6. As determined in Step 3, place the required
TOOL-4201-C or equivalent. Force ring gear into amount of differential bearing shims on the ring
mesh with the pinion. Rock ring gear to allow the gear hub of the differential case. For example, if
teeth of the gears to mesh. With force still applied the reading in Step 3 was 1. 14mm (0.045 inch),
to the differential case, set indicator at zero. place 1. 14mm (0.045 inch) of differential bearing
shims on the hub of the ring gear side of the
differential case.
7. Install the bearing cone on the ring gear side of
the differential case. Drive the bearing onto the
hub using Differential Bearing Cone Replacer
D81T-4221-A or equivalent as shown.
DIAL INDICATOR
WITH BRACKETRY
TOOL-4201-C
DIFFERENTIAL SIDE
BEARING REPLACER
081 T-4221-A
E8403-e
3. NOTE: This reading will be the necessary amount

of differential bearing shims (4067) required
between the differential case and differential
bearings on the ring gear side.
Force the differential case (ring gear) away from
the pinion gear to obtain an indicator reading.
Repeat until the same reading is obtained each
time.
STEP PLATE
4. Remove indicator and differential case from the DSOL-630-7
E8407-e
carrier.
5. Remove master bearings from differential case. 8. To determine the correct amount of differential
pinion side of the differential case, subtract the
reading obtained in Step 3 from the total
'differential case end play. Total differential case
end play was determined under Steps 10 and 11
of Differential Case Assembly. When this amount
is determined, add 0.36mm (0.015 inch) to the
amount. This is the required amount of differential
pinion side of the differential case.
For example, total differential case end play was
2.30mm (0.091 inch). The reading in Step 3 of
this procedure was 1. 14mm (0.045 inch), which,
when subtracted from 2.30mm (0.091 inch),
gives 1. 16mm (0.046 inch). 0.36mm (0.015 inch)
is added to give 1.52mm (0.061 inch) of
differential bearing shims to be placed on the hub
of the drive pinion side of the differential case.
9: Place the required amount of differential bearing
shims on the hub of the drive pinion side of the
differential case.
E7119-D

ALL RIGHTS RESERVED
10. Install the bearing cone on the hub of the drive 16. Install bearing caps. Make sure the letters
pinion side of the differential case. Place Step stamped on the caps correspond with those on
Plate Adapter D80l-630-7 or equivalent on the the carriers. Tighten bearing capscrews to
ring gear side bearing to protect the bearing specifications listed at the end of this section.
during installation of the drive pinion side bearing.
11. Place the bearing on the drive pinion side hub and
drive it on using Differential Bearing Cone
Replacer 081 T-4221-A or equivalent.
12. CAUTION: Do not spread carrier over
0.38mm (0.015 inch).
Install spreader and indicator to carrier. Remove
indicator.
DIFFERENTIAL
HOUSING SPREADER
TOOL-4000-E
o.A
MATING LETTERS ~E '
6670-1
A
17. Check ring gear and pinion backlash in three

• Backlash tolerance is 0.13-0.23mm
(0.005-0.009 inch) and cannot vary more than
0.05mm (0.002 inch) between points checked.
• High backlash is corrected by moving the ring
SPREADER MUST ACCOMODATE 292mm gear closer to the pinion.
(11.50 INCH) DISTANCE BETWEEN ~ OF
HOLE TO ~ OF HOLE • low backlash is corrected by moving ring gear
E8014-,8
away from the pinion.
13. Assemble differential bearing cup (4222) to • These corrections are made by switching
differential bearing cones. differential bearing shims from one side of the
14. NOTE: Avoid nicking the teeth of the ring gear differential case to the other.
and pinion during assembly.
Install differential into carrier. Use a rawhide
hammer to seat differential into crossbore of
carrier.
15. Remove the spreader from the differential case.
18. Obtain a gear tooth contact pattern. Refer to

Gear Tooth Contact Pattern Check in this section
prior to complete reassembly.
E8018-1A

ALL RIGHTS RESERVED
19. The cover face of the carrier and the flat surface 22. Install the axle shafts as described under Axle
of the axle housing cover (4033) must be free of Shaft Removal and Installation in this section.
any oil film or foreign material. 23. Connect the steering linkage to the steering
• Apply RTV Silicone Rubber Sealer knuckle.
D6AZ-19562-AA (clear) or -BA (black) sealant
or equivalent meeting Ford specifications
ESB-M4G92-A or ESE-M4G 195-A to surface
of the axle housing cover. Make sure the Gear Tooth Contact Pattern Check
sealer bead (3. 18-6.35mm [ 1/8 to 1/4 inch]
wide) is laid on the inside of the cover screw SPECIAL SERVICE TOOL(S) REQUIRED
holes. The bead is not to pass through the
holes or outside of the holes. Description Tool Number
U-Joint Tool T74P-4635-C
1. When rolling a tooth pattern, use a special

marking compound (tube) to obtain gear tooth
mesh contact pattern.
2. NOTE: A marking compound mixture that is too
wet will run and smear; too dry a mixture cannot
be pressed out from between the teeth.
To check the gear tooth contact, paint the gear
teeth with the special marking compound.
3. Rotate ring gear (use a box wrench on the ring
gear attaching bolts as a lever) several complete
revolutions in both directions or until a clear tooth
contact pattern is obtained.
Incorrect adjustment can be corrected by
readjusting the ring gear or the pinion.
20. Install two cover screws into axle housing cover

at 8 o'clock and 2 o'clock positions. Use these
two holes to guide axle housing cover into
position on the carrier.
21. Install remaining screws. lighten alternately and
evenly. lighten screws to 41-54 N·m (30-40 Ib-ft).
Allow one hour curing time before filling
carrier with the proper amount of specified
lubricant and vehicle operation.
ALL RIGHTS RESERVED
Tooth Patterns
ACCEPTABLE TOOTH PATTERN UMITS

ANY COMBINATION OF DRIVE AND COAST
TOE PATTERNS SHOWN PERMISSIBlE
TOE
5 5
2 2
3 7 3
4 COAST E811&-2A
DRIVE
5. The previous illustration shows acceptable tooth c. Some clearance between the pattern and the
patterns for all axles. In general, desirable tooth top of the tooth is desirable.
patterns should have the following d. There should be no hard lines where the
characteristics: pressure is high.
centered on the teeth.
ALL RIGHTS RESERVED
6. An individual gear set need not conform exactly to

the ideal pattern to be acceptable. Any .
combination of drive and coast patterns shown IS DRIVE SIDE COAST SIDE
acceptable.
HEEL TOE TOE HEEL
THINNER DRIVE PINION

SHIM REQUIRED.
THICKER DRIVE PINION

SHIM REQUIRED.
ROOT
E8197·C
RING GEAR TOOTH
COAST SIDE
HEEL 9. NOTE: If the patterns are not correct, make the
changes as indicated. The differential case
(4204) and drive pinion will have to be removed
from the carrier housing to change a differential
bearing shim (4067).
If the drive pinion shims are correct, decreasing
backlash moves the ring gear closer to the pinion.
Drive pattern (convex side of gear) moves slightly
E8198-8 lower and toward the toe. Coast pattern
(concave side of gear) moves lower and toward
7. NOTE: When making pinion position changes, the toe. Increasing backlash moves the ring gear
drive pinion shims should be changed ~n the ra~ge away from the pinion. Drive pattern moves
of .05mm (.002 inch) to .10mm (.004 Inch) until slightly higher and toward the heel. Coast pattern
correct pattern has been obtained. moves higher and towards the heel.
Since each gear set rolls a characteristic pattern,
the patterns shown are considered acceptable
and should be used as a guide. The drive pattern DRIVE SIDE COAST SIDE
is rolled on the convex side of the tooth, and the
coast pattern is rolled on the concave side.
8. The movement of tooth contact patterns with HEEL TOE TOE HEEL
changes in shimming can be summarized as
follows:
a. Thinner drive pinion shim, with the backlash DECREASE BACKLASH.
set to specification, moves the pinion farther
from the ring gear.
b. Thicker drive pinion shim, with the backlash
set to specification, moves the pinion closer
to the ring gear. INCREASE BACKLASH
E8198-C
ALL RIGHTS RESERVED
. 10. NOTE: Backlash tolerance is 0.13-0.23mm 3. Remove the snap rings that retain the bearings in
(0.005-0.009 inch) and cannot vary more than the yoke and axle shaft.
0.08mm (0.003 i~~ch) between the three points. 4. Position U-Joint Tool T74P-4635-C on the shaft
NOTE: When a change in backlash is required, and press the bearings out of the yoke. If the
differential bearing shims should be changed in bearing cannot be pressed completely out of the
the range of 1-1 / 2 times the amount of backlash yoke, remove the bearing with vise grip or
required to bring the gears into specification. For channel lock pliers. Mark the yoke and shaft so
example, if the backlash needed to be changed they can be assembled in the same position.
by .10mm (.004 inch), the differential bearing 5. Reposition the U-Joint Tool T74P-4635-C to
shims should be changed by .15mm (.006 inch) press on the spider to remove the bearing from
as a starting point. The actual amount of backlash the opposite side of the yoke.
change obtained will vary depending upon the
ratio and gear size. 6. Remove the yoke from the spider.
Check ring gear backlash by installing a dial Assembly
indicator on the carrier housing. Check ring gear 1. Position the spider in the axle shaft and press the
and pinion backlash at three equally spaced bearing 6mm (1 / 4 inch) below the axle shaft
points on the ring gear. surface using Pinion Bearing Cone Remover
11. If backlash is high, the ring gear must be moved D79L-4621-A or equivalent.
closer to the pinion, by moving differential bearing 2. Remove the tool and install a new snap ring.
shims from the ring gear side to the opposite side.
If backlash is low, the ring gear must be moved 3. Start a new bearing on the opposite side of the
away from the pinion by moving differential axle shaft.
bearing shims from the ring gear side to the 4. Install the U-Joint Tool and press the bearing until
opposite side. the snap ring of the opposite bearing contacts the
axle shaft.
5. Remove the tool and install a new snap ring.
Axle Shaft 6. Install the yoke on the spider in position marked
during disassembly.
Disassembly
7. Install two new bearings and snap rings in the
1. Remove the axle shaft as described under Axle yoke and spider in the same manner as the axle
Shaft Removal and Installation in this section. shaft.
2. NOTE: Sometimes on disassembly, the spacer 8. Check the U-joint for freedom of movement. If a
installed in the thrust washer assembly will binding condition results, tap the ears of the axle
become separated from the thrust washer. shaft sharply to relieve the binding. DO NOT
Although this is not serious, replacing the entire INSTALL AN AXLE SHAFT IF THE U-JOINT
assembly would be a good idea. SHOWS SIGNS OF BINDING.
Remove the spindle thrust washer assembly from 9. Install the rubber rolling diaphragm seal on the
the axle shaft. axle shaft. The lip of the seal should face towards
the front wheel spindle (3105).
FRONT SPINDLE
AXLE THRUST
SHAFT WASHER
~E._
3A329
E6654-E
ALL RIGHTS RESERVED
SPECIFICATIONS
DANA AXLE ADJUSTMENTS

Description Specification Description Specification
Backlash Between Ring Gear and Pinion 0.13-0.23mm Pinion Bearing Preload 2.26-4.52 N·m
(0.005-0.009 Inch) (with New Bearings) (20-40 Lb-In)
Backlash Maximum Variation Between Teeth 0.05mm Pinion Bearing Preload 2.26-4.52 N·m
(0.002 Inch) (with New Bearings) (20-40 Lb-In)
AXLE LUBRICANT CAPACITIES

Approximate Capacities
Axle Model Ford Specification U.S. Pts. Imp. Pts. Liters
60 Premium Rear Axle Lubricant, C6AZ-19580-E or Equivalent Meeting Ford 5.9 4.9 2.8
Specification ESW-M26105-A

Description N·m Lb-Ft Lb-In SPECIAl SERVICE TOOLS REQUIRED
Pinion Shaft Nut 298-379 220-280 - Tool Number /
Differential Bearing 109-122 80-90 - Desc'rlptlon illustration
Capscrews T50T-100-A
~
Ring Gear Bolts / Nuts (Grade 136-162 100-120 - Impact Slide Hammer
9)
T50T-1OG-A
Ring Gear Bolts / Nuts (Grade 176-190 130-140 -
9), C7 Lines on Bolt Head T56T-4616-B
Oil Filler Plug
U-Joint U-Bolt Nuts
28-34
21-27
21-25
15-20
-
-
81~@~
Cover-to-Housing Bolts 41-54 30-40 - T58T-4818-8
Tracking Bar Nut and Bolt 221-275 163-203 - T79P-4020-A
Stabilizer Link Nut 28-48 21-35 - Pinion Depth Gauge
Stabilizer Bar U-Bolt 65-92 48-68 - ~ ~
Spindle. Connecting 95-135 70-100 - ~ n
Rod-to-Steering Knuckle
Castellated Nut ~~~
1Ilr--;L"~
!O
Stabilizer Bar Bracket U-Bolt 65-92 48-68 - ~
Lower Bait Joint Nut
Upper Ball Joint Nut
203
95
150·
70·
-
-
~ II
T79P-4020·A
Spindle-to-Steering Knuckle 68-81 50-60 -
Nuts T56T-4676-B
-
~
Outer Locknut 217-277 160-204 Pinion Seal Replacer
Capscrews - 6 Torx@-Head 4.0-6.0 - 35-53 T58T-4878-B
a Requires specific tightening sequence for proper

installation. Refer to ball joint installation procedure in this T57T-4851-B
section for procedure. Companion Flange Holding Tool
.~
T57T-4851-B
T64P-3590-F
Pitman Arm Puller
~ T84P-3590-F
(Continued)

ALL RIGHTS RESERVED
05-038-33 Axle, Front Drive, Dana Model 60 Monobeam 05·038·33

(Continued)
Tool Number/ Tool Number /

De8crlptlon IIIu8tration De8crlptlon Illustration
T65L-4851-8 T92T-3010-B
~
Companion Flange Remover Ball Joint Remover / Replacer
(~O
,Ii' (Inside)
T74P-4635-C T92T·3010-8
U-Joint Tool
~ T92T-4000-A
Spindle Seal Replacer
T75L-1165-B
T74P-4I3I-C
~
~
T92T-40G0-A
T'I!IL-11'"
T75L-1165-DA
Axle Bearing / Seal Replacer Tool Number Description
~ T75L-1185-0A
C>78P-4201-B
D79L-4621-A
Dial Indicator / Magnetic Base
Pinion Bearing Cone Remover
D80L-100-H Actuator Pin
T75T-1176-A D80L-100-W Bridge Assembly
Threaded Drawbar
~
D80L-100-U Collet (1-1 /2 to 1-3/4Inch)
D80T-4020-F48 Gauge Tube
D81L-4000-A Driver Handle
T7IT-1171-A
D81L-4220-A Pinion and Carrier Bearing Puller
T77F-1102-A
081 T-4221-A Differential Bearing Cone Replacer
Bearing Cup Puller
~
D81T-4222-D Dummy Differential Bearings
D81T-4628-A Pinion Bearing Cup Remover
~- D81T-4628-D Pini~Bearing Cup Remover
D85T-1197-A Spanner Locknut Wrench
T77F-1102-A
D81T-3010-A 1 'Ball:loint Adapter Set
T77L-9533-B
D81T-30 10-A3 Ball Joint Adapter Set
~
Jet Plug Remover
.f,
D81T-3010-A4 Ball Joint Adapter Set
~ T77L-I533-8
D81T-30 10-A5 Receiver Cup
a
T80T-4000-R D80L-630-7 Step Plate Adapter
TOOL-4858E Companion Flange Replacer
TOOL-1175-AC Seal Remover
TIOT-4CJOO.R
TOOL-4000-E Differential Housing Spreader
T80T-4000-W
Driver Handle
~ ROTUNDA EQUIPMENT
TIOT-4000-W Model Description
T83T-4676-A 077-00008 Low Lift Transmission Jack
Pinion Seal Replacer
Q@
TI3T-467I-A
T92T-30 10-A
Ball Joint Remover / Replacer
(Outside)
([J T92T·3010..A
(Continued)

ALL RIGHTS RESERVED
05-03C-1 Wheel Hubs and Bearings, Front Wheels, 4-Wheel Drive 05-03C-1
SECTION 05·03C Wheel Hubs and Bearings, Front

Wheels, 4·Wheel Drive
VEHICLE APPLICATION ••••••••••••••••••••••••..•••••••••••.•••••OS·03C-1 REMOVAL AND INSTALLATION (Cont'd.)
DESCRIPTION AND OPERATION Locking Hubs, Manual, F-250, F-3S0 Vehicles
Locking Hubs ••••••••••••••••.•••••••••••••••••••.•••••••••••••••••05-03C-1 . Built Before April 1995 •••••••••••••••••••••••••••••••••••••OS-Q3C-5
DIAGNOSIS AND TESTING DISASSEMBLY AND ASSEMBLY
Inspection and Verification •••.•••••••••••••••••.••••••••••••OS·03C-2 Wheel Grease Seal and Bearing, Front •••••••••••••••OS-Q3C-13
Manual Locking Hubs •.•••••••••••••••••••.•••••••••••••••••05-03C-2 ADJUSTMENTS
Pinpoint Test •••••••••••••••••••••••••••••••••••••••••••••••••.•••••OS·03C-4 Front Wheel Bearing, Automatic Locking
Symptom Chart •••••••••••••••••••••••••••••••••••••••.•••••••••••05-03C-3 Hubs •••••...•••••••••••••••••••••••••••••••.••••••••••••.••••••••• 05-Q3e--~
REMOVAL AND INSTALLATION Front Wheel Bearing, with Manual Locking .
Locking Hubs, Automatlc ••••••••••••••••••••••••••••••••.••05-03C-10 Hubs •••••••••••..••••••••••••••••••••••••••••••••••••••••••••••••• ()f~3C-16
Locking Hubs, Manual, F-150 and Bronco - SPECIFICATIONS•••••••..•••••••••••••••••••••••••••••••••••••••••Q&-03C-17
All, F-250 and F-3S0 Vehicles Built After SPECIAL SERVICE TOOLS/EQUIPMENT••••••••••••••••05-03C-17
March 1995•••••••••••••••••••••••••••.•••••••••••••.•.••••••••••05-03C-7
j " ~
VEHICLE APPLICATION
F-150, F-250, F-350, and Bronco
Locking Hubs When the 4x4 button is depressed, the electronic

The hublocks on F-150, F-250, F-350 and Bronco 4x4 control module energizes the electronic clutch coil in
vehicles equipped with four-wheel drive either the transfer case. This accelerates the front axle
automatically or manually actuate the front driving shafts up to the same speed as the front wheels. As
~~When actuated, the hublock body locks the hub
the axle shafts begin to rotate, they engage the
and wheel (1007) and tire assembly to the halfshaft automatic hublocks located at each wheel end. After
(3A329). When released, the axle shaft is disengaged approximately 5 seconds, the transfer case clutch coil
fror(fte~front disc brake hub and rotor (1102) and the
turns off. A stepper motor located on the back of the
wheel rotates freely on the front wheel spindle (3105). transfer case then locks up the transfer case via a
camming mechanism and a locking collar. TIfe entire
F-350 4x4 vehicles equipped with dual wheel rear sequence takes only a few seconds.
axles (4001) have the outer wheels and tires attached
with integral two-piece swiveling wheel hub bolts To disengage the transfer case, again depress the
(1107). 4x4 button. This will unlock the transfer case but the
automatic hubs will remain locked. To unlock the hubs,
WARNIN~i50 NOT USE OLDER DESIGN WHEEL back up the vehicle for at least 10 feet, then contiriUe
HUB BOl"T§·(CONE-SHAPED, ONE-PIECE) TO in the original direction. Because the front axle has
REPLACE :THE CURRENT INTEGRAL TWO-PIECE been disengaged from the transfer case, the hubs will
SWIVELING WHEEL HUB BOLTS. OLDER DESIGN remain unlocked.
WHEEL HUB BOLTS CAN COME lOOSE DURING
Buzzing and ratcheting noises were a constant
VEHICLE OPERATION. DO NOT USE OLDER
concern with older 4x4 vehicles. These noises
DESIGN WHEELS, WHICH .I:'IAVE CONE-SHAPED
occurred usually when shifting into four-wheel drive
SEATS FOR THE WHEEL HUB BOLTS, ON THIS
VEHICLE. DO NOT USE THE CURRENT DESIGN after starting a vehicle that had been sitting cold for
several hours. The noises would also occur just after
WHEELS OR WHEEL HUB BOLTS ON OLDER
shifting from four-wheel drive to two-wheel drive. Cold
DESIGN VEHICLES. USE OF INTERMIXED
WHEELS CAN DAMAGE THE WHEEL MOUNTING weather was another factor that produced the noise
concerns. Colder temperatures increased the
SYSTEM AND COULD RESULT IN WHEELS
viscosity of the axle lubricant, resulting in a much
COMING lOOSE DURING OPERATION.
higher torque requirement for the transfer case clutch
The Touch Drive 4x4 system allows the driver to which could only rotate the pinion gears enough to
engage four-wheel drive at the touch of a button cause the hubs to partially lock, which resulted in a
instead of pulling a shift lever. This button is connected ratcheting noise.
to an electronic control module which controls the
functions necessary to engage the transfer case
(7A195).

ALL RIGHTS RESERVED
The newer vehicles, however, utilize a synthetic axle To engage the hubs for four-wheel drive (F-150 and
lubricant with low viscosity and a transfer case clutch Bronco - all, F-250, F-350 vehicles built after March
with a higher output. Both innovations allow for 4x4 1995), grasp the locking bar in the center of the hub
operation in extreme temperature conditions. and rotate it clockwise to the LOCK position. The
Noise concerns in two-wheel drive, just after shifting arrow on the locking bar must line up with the marker
from four-wheel drive, can occur if one of the hublocks on the hub at the LOCK position. To disengage the
fails to disengage. As the vehicle moves forward, the hubs for two-wheel drive, grasp the locking bar and
one hublock that has failed to disengage will rotate its rotate it counterclockwise toward the FREE position
axle shaft through the differential and attempt to until the arrow on the locking bar ~s lined up with the
rotate the other axle shaft in the opposite direction. marker on the hub at the FREE position.
This is called differential motoring torque. As this
torque attempts to turn the other axle shaft through F-150 and Bronco (All), F-250, F-350 (Vehicles Built
the differential gears, that shaft's hublock will attempt After March 1995)
to engage, which will result in a ratcheting or buzzing
noise.
This type of noise concern is usually found on axles
that have very few 4x4 miles on them. As the front
axle accumulates 100 to 200 miles of locked hub
operation, the axle will break in, which reduces the
amount of differential motoring torque significantly. To
accomplish this, engage four-wheel drive and then
shift out of it without disengaging the hubs. This will
break in the axle. Should the vehicle be backed up
during this time period, the hubs will disengage and will
LOCKING
have to be locked again by repeating the engagement BAR
procedure.
E9798-A
The F-150 and Bronco has a new design manual
locking hub. The F-250 and F-350 vehicles built after
March of 1995 will also have the new design manual
locking hub. Prior to April of 1995, F-250 and F-350
vehicles have the same manual locking hub used on DIAGNOSIS AND TESTING
1994 F-250 and F-350 vehicles. Both caps are
shown. Inspection and Verification
The manual locking hubs must be engaged and Manual Locking Hubs
disengaged by hand. To engage the hubs for
four-wheel drive (F-250, F-350 vehicles built before Manual locking hubs are simple to diagnose. Place the
April 1995), grasp the locking bar in the center of the transfer case (7A195) in two-wheel drive and raise the
hub and rotate it clockwise to the LOCK position. The front wheels (1007) off the ground. When in the
arrow on the locking bar must line up point-to-point unlocked position, the wheels should be able to turn
with the arrow on the hub at the LOCK position. To freely. Then lock each of the front hubs and rotate the
disengage the hubs for two-wheel drive, grasp the front wheels. The additional load of the drivetrain
locking bar and rotate it counterclockwise toward the . components should be felt once the hub has been
FREE position until the arrow on the locking bar is lined engaged. In addition, the axle and front driveshaft
up point-to-point with the arrow on the hub at the FREE should be moving along with the wheel. Disengage the
position. hubs aF:ld repeat the procedure to check that the hubs
have smoothly disengaged.
Manual Locking Hub - F-250 and F-350 Vehicles
Built Before April 1995
F8421-A

ALL RIGHTS RESERVED
Automatic Locking Hubs Driving through several turns while traveling in different
NOTE: While the vehicle is hoisted, shift into directions will make sure that both sides of the hub
four-wheel drive from a dead stop and not while rear teeth have been tested under load. Hubs that are not
wheels are rotating in order to avoid slamming the sufficiently engaged will "pop" out when loaded. This
hublocks into the lock position. is due to the driveline releasing windup and is an
indication of hub malfunction.
Raise vehicle on a hoist so that all wheels are off the
ground. Start engine (6007) with vehicle in neutral and If slippage is suspected, mark the tire and axle with
transfer case in two"'wheel drive. Front wheels should chalk (after locking the hub) and apply a heavy torque
spin freely by hand. Put transfer case in 4WD and put load several times. Then inspect your original indexing
vehicle in gear. Front and rear wheels should rotate marks. If they are no longer aligned, the hubs are not
together. Put vehicle in neutral and spin front wheels remaining locked when under load. They will have to
by hand in the forward direction. The front axle and be replaced.
front driveshaft should rotate with the wheels. The Should hublocks become submerged in water or mud
additional load of the drivetrain components should be for a long period of time, water may get past the seals
felt once the hub has been engaged. To disengage the and into the hubs and axle. In this case, all water must
hubs, spin the wheels in the opposite direction until an be expelled from the system. The axle must be
audible "click" is heard. Spin wheels forward again drained by loosening the axle cover and 4x4 Gear Oil
and they should rotate freely without the axle and F1TZ-19580-A (WSL-M2C191-A) used to refill the
driveshaft rotating. Repeat the procedure, only shift axle (F1TZ-19580-A has no equivalent). Disassemble
into four-wheel drive and put the vehicle in reverse. the hubs using procedures in this section and repack
This time the hubs should release when the front the wheel bearings using procedures in this section
wheels are spun in the forward direction. and dry off the hublocks. Reassemble hubs using
procedure in this section. Refer to 05-03A or 05-038
Road Test for replacement of outer axle shaft seals or spindle
When checking front hubs for proper operation, road inner seal and bearing.
test the vehicle to make sure the hubs will remain
engaged while under load. This is accomplished by
engaging four-wheel drive and taking the vehicle
through several turns (both forward and backward) on
dry pavement. This will put an additional load on the
front wheel at the outside of the turn because it is
traveling the greatest distance.
Symptom Chart
FRONT AXLE NOISES IN FOUR-WHEEL DRIVE

• Ratcheting or Buzzing Noise in

Front Axle in Two-Wheel Drive,
• Right or left side hublock. • REPLACE hublocks as necessary.
REFER to Pinpoint Test A.
Shortly After Four-Wheel Drive
Usage
• Popping Sound from Front Axle

When in Four-Wheel Drive
• Right or left side hublock. • REPLACE hublocks as necessary
and INSPECT associated
camming. REPLACE camming if
damaged.
.-
1995 F-150, F-250, F·350, Bronco, F·Super Duty Powertrain, Drivetrain July 1994
ALL RIGHTS RESERVED
Pinpoint Test
PINPOINT TEST A: NOISE WHILE ENGAGING FOUR-WHEEL DRIVE
A1 I VERIFY LUBRICANT
• Verify front axle differential lubricant is 1.66 litres
(56 oz.) of 4x4 Gear Oil F1TZ-19580-A
Yes ~ GOtoA2.
~ REPLACE differential
No
(WSL-M2C 191-A). lubricant with 1.66 litres
NOTE: There is no equivalent for F 1TZ-19580-A (56 oz.) of 4x4 Gear Oil
(WSL-M2C 191-A). Do not substitute any other F1TZ-f9580-A
lubricant. (WSL-M2C 191-A). GO to
A2.
• Is lubricant to specifications?
A2 I VERIFY HUBLOCKS ARE OPERATIONAL
• Verify that the hubs lock and unlock using procedure
in this section. See Inspection and Verification in
Yes ~ ROAD TEST vehicle. GO
toA3.
~':.}
-. this section.
Do hublocks work properly?
No ~ INSPECT right and left
side hublocks and
REPLACE as necessary.
INSPECT associated
camming and REPLACE
camming if damaged.
REPEAT A2. If hublock is
satisfactory, GO to A3.
A3 I VERIFY OUTPUT OF TRANSFER CASE CLUTCH
• While road testing vehicle, push 4x4 button. Yes ~ Repair is complete.
• Does vehicle shift to 4x4 mode with no buzzing or
ratcheting noise?
No ~ REPLACE clutch coil,
housing, lockup collar,
lockup fork, return spring
and sleeve spring.
REPEAT road test.
REFER to Section
07-07A.

ALL RIGHTS RESERVED
Locking Hubs, Manual, F-250, F-350 Vehicles

Part
Built Before April 1995
Manual Locking Hubs - F-250, F-350 Vehicles Built 3 3299 Integral Spacer Needle
Before April 1995 Bearing Seal
4 3123 Bearing, Caged Needle
6 1190 Wheel Hub Grease Seal
7 4222 Inner Wheel Bearing Cup
y (with Bearing - 4221)
8 1102 Front Disc Brake Hub and
Rotor
(with Bearing - 4221)
10 - Pin (Part of 1195)
11 1195 Inner Locknut
12 1198 Lockwasher
13 1197 Outer Locknut
14 1K105 Hub Body
15 1K104 Snap Ring
16 1K104 Lockring
17 1K104 Cap
18 1K104 Capscrew
A - While Rotating the Front
Disc Brake Hub and Rotor
Back and Forth, Tighten the
Inner Locknut to 68 N·m (50
Lb-Ft) to Seat the Bearings.
Back Nut Off 90 Degrees
(1/4 Turn).
(160-205 Lb-Ft)
(35-53 Lb-In)
E9799-A
Part
1 3A329 Halfshaft
2 3C132 Rolling Diaphragm Seal
(RDS) (Axle)
(Continued)

ALL RIGHTS RESERVED
REMOVAL .AND INSTALLATION (Continued)

HALFSHAFT
1. Separate cap assembly from hub body by (PART OF FRONT
removing the six Torx@ head capscrews. AXLE SHAFT)
3A329
HUB
BODY
F4657·E
3. Remove the lockring seated in the groove of the
front disc brake hub and rotor (1102).
F4655-C
Part
1 1K104 Torx~ Head Capscrew
2 1K104 Lockring F4858-C
3 1K105 Body Assembly
4 1K104 Snap Ring (F-250 Only)
5 1K106 Cap Assembly
(35-53 Lb-In)
2. NOTE: F-350 4 x 4 no longer utilizes the snap

ring, although F-250 4x4 vehicles still do.
Remove the snap ring that retains the halfshaft
(3A329) in the hub body assembly.

ALL RIGHTS RESERVED
4. Remove the body assembly from the front disc Locking Hubs, Manual, F-150 and Bronco -
brake hub and rotor. If the body is difficult to All, F-250 and F-350 Vehicles Built After
remove, install two capscrews and pull the body
assembly out of the front disc brake hub and
March 1995
rotor.
Manual Locking Hubs - F-150 and Bronco
BODY
ASSEMBLY
F. .9·D
order. lighten six Torx(!) head capscrews to 4-6 N·m
(35-53Ib-in). Do not pack the cap with grease.
Excessive grease can cause excessive dialing effort.
E9800-A
Part
1 3A329 Hallshaft
2 3C132 Rolling Diaphragm Seal Axle
3 3299 Integral Spacer Needle
Bearing Seal
6 3254 Outer Spindle Rolling
Diaphragm Seal
Rotor
(Continued)

ALL RIGHTS RESERVED
'05-03C-8 Wheel Hubs and Bearings, Front Wheels, 4-Wheel Drive 05-03C-8
Manual Locking Hubs - F-250, F-350 Vehicles Built

~.rt After March 1995
11 - Pin (Part of 1195)
13 1198 Lockwasher
(Part of 3B458)
(Part of 3B458)
(Part of 3B458)
18 3B457 C-Ring
19 1K105 Hub Body
20 1K104 Lockring
21 1K104 Cup
22 1K104 Capscrew
A - While Rotating Front Disc
Brake Hub and Rotor,
Tighten Inner Locknut to 68.
N·m (50 Lb-Ft) to Seat
Bearing. Back Nut Off 90 '
Degrees (1/4 Turn).
(160-205 Lb-Ft)
(35-53 Lb-In)
E9801-A
Part
1 3A329 Halfshaft
(Axle)
Bearing Seal
(with Bearing)
Rotor
(with Bearing)
10 - Pin (Part of 1195)
12 1198 Lockwasher
(Continued)

ALL RIGHTS RESERVED
/
Part
14 - Steel ThrustVVasher
(Part of 3B458)
15 - Plastic Thrust VVasher
(Part of 3B458)
16 - Splined Thrust VVasher
(Part of 3B458)
17 3B457 Snap Ring
18 1K105 Hub Body
19 1K104 Lockring
20 1K104 Cap
21 1K104 Capscrew HUB BODY
A - VVhile Rotating Front Disc 1K105
Brake Hub and Rotor.
E9803-A
Tighten Inner Locknut to 68
N·m (50 Lb-Ft) to Seat
Bearings. Back Nut Off 90 2. Remove the lockring seated in the groove of the
Degrees (1/4 Turn).
front disc brake hub and rotor (1102).
(160-205 Lb-Ft)
(35-53 Lb-In)

1. Separate cap assembly from hub body by
removing the three Torx@ head capscrews.
FRONT DISC
BRAKE HUB
AND ROTOR
1102
CAP
ASSEMBLY
1K104
F4858-C
TORX(!~ HEAD
SCREWS
1K104
E9802-A
ALL RIGHTS RESERVED
3. Remove the body assembly from the front disc Locking Hubs, Automatic
brake hub and rotor. If the body is difficult to
remove, install two capscrews and pull the body Automatic Locking Hub - F-150 and Bronco
assembly out of the front disc brake hub and
rotor.
BODY
ASSEMBLY
Fa&9-D

order. Tighten three Torx@ head capscrews to 4-6 N·m
(35-53Ib-in).
• Do not pack the cap with grease. Excessive grease
can cause excessive dialing effort.
E9804-A
Part
1 3A329 Halfshaft
2 3C132 Rolling Diaphragm S~al
(RDS), Axle
Bearing Seal
6 3254 Outer Spindle Rolling
Diaphragm Seal
Rotor
11 3B549 Wheel Retainer Key
(Continued)
ALL RIGHTS RESERVED
05-03C-11 Wheel Hubs and Bearings, Front Wheels, 4-W.heel Drive 05-03C-11
Automatic Locking Hub - F-250, F-350

Part
(Part of 38458)
(Part of 38458)
14 1K104 Lockring
15 1K104 Capscrew
16 1K104 Cap
17 1K105 Hub Body
18 38457 C-Ring
(Part of 3B458)
20 - Cam Assembly
(Part of 1K105)
21 - Wheel Retainer (Nut)
(Part of 1K105)
(35-53 Lb-In)
B - While Rotating Front Disc
Brake Hub and Rotor,
Tighten Until Snug to Seat
Wheel Bearings. Back Nut
Off 90 Degrees (1 /4 Turn).
Tighten to 1.8 N·m
(16 Lb-In)
E9805-A
Part
1 3A329 Halfshaft
(RDS), Axle
Bearing Seal
4 3123 8earing, Caged Needle
(with Bearing 4221)
Rotor
(8earing - 4221)
10 38549 Wheel Retainer Key
(Part of 3B458)
(Part of 3B458)
(Continued)

ALL RIGHTS RESERVED
Removal
Part
CAUTION: Do not drop hub components during
removal and installation.
13 1K104 Lockring
1. Separate cap from body assembly by removing
14 1K104 Capscrew
the three capscrews, using Torx@ bit TX25 or
15 1K104 Cap equivalent, from the cap.
16 1K105 Hub Body
17 3B457 Snap Ring 2. Remove cap.
'.1.8.. - Plastic Thrust Washer 3. Remove the lockring seated in the groove of the
., (Part of 3B458) front disc brake hub and rotor (1102).
;.,
19 ' - Cam Assembly 4. Remove the body assembly from the front disc
(Part of 1K105)
brake hub and rotor.
(Part of 1K105)
(35-53 Lb-In)
B - While Rotating Front Disc
,~ <f Brake Hub and Rotor,
Tighten Until Snug to Seat
Wheel Bearings. Back Nut
Off 90 Degrees (1 /4 Turn).
Tighten to 1.8 N·m
(16 Lb-In)
Automatic Lock Hub, Exploded View - Typical
6
®
E9806-A
Part Part
1 1K104 Cap 9 - Splined Thrust Washer
2 1K105 Hub Body (Part of 38458)
3 38457 Snap Ring 10 1K104 Lockring
4 - Plastic Thrust Washer 11 1K104 Capscrews (3)
(Part of 3B458) A - While Rotating Front Disc
5 - Cam Assembly 8rake Hub and Rotor,
(Part of 1K 105) Tighten Wheel Retainer (Nut)
Until Snug to Seat Wheel
8earings. Back Nut Off 90
(Part of 1K 105)
Degrees (1 /4 Turn). Tighten
7 1K104 Lockring to 1.8 N·m (16 Lb-In).
8 - Steel Thrust Washer B - Tighten to 4-6 N·m
(Part of 3B458) (35-53 Lb-In)
(Continued)
5. Remove C-washer or snap ring from stub shaft 7. Remove cam assembly. Pull t9 remove.
groove.
6. Remove spacers (thre~ thrust washers) from
shaft.
ALL RIGHTS RESERVED
05~03C-13 Wheel Hubs and Bearings, Front Wheels, 4-Wheel Drive 05-03C-13
8. If front disc brake hub and rotor and front wheel Sodium-base grease is not compatible with
spindle (3105) are to be removed, refer to Wheel lithium-base grease and should not be intermixed.
Grease Seal and Bearing, Front Replacement and Therefore, before lubricating front or rear wheel
Repacking. bearings (1225), thoroughly clean all old grease from
the bearing and front disc brake hub and rotor (1102).
Installation
If bearing adjustment does not eliminate looseness or
1. Align the fixed cam retaining key on the cam rough and noisy operation, clean, inspect and repack
assembly (garter spring inboarc) with the keyway the front disc brake hub and rotor and bearings with
on the spindle. Firmly press the cam assembly on specified wheel grease. If bearing cups or the <?,qne
the wheel retainer nut. and roller assemblies are worn or damaged, rePlace.
2. Install 3 ring washer set. (1 st Metal, 2nd Plastic, Disassembly
3rd Splined) and retainer rockring on C-clip. It may
be necessary to push the axle ou~b.oar~ fro,m 1. Raise vehicle and install safety stands.
backside of knuckle. Be sure retaining nng IS 2. Remove the locking hubs. Refer to locking hub \J~1;.
seated in groove properly. removal and installation procedure in this ~ection.
3. CAUTION: Rotate moving cam stop (use any 3. Remove the wheel and tire. Refer to Sectio~~. _.-:-
one of thr~e) to the !lne o'clock P!J~ition in 04-04 in the Body, Chassis manual. -.~~;.~ .~'.'~
relationship to the fixed cam retaining key.
4. CAUTION: Do not let the disc brake caiiPer~~
CAUTION: Do not force body assembly into (2B120) hang only by the hose, or damage
front disc brake hub on rotor if body may occur to the hose or disc brake caliper.
assembly will not fit. Recheck alignment of
all components. Remove the disc brake caliper. Refer to Section
06-03 in the Body, Chassis manual. Securely wire
NOTE: The hubs should not be packed with the disc brake caliper to the frame.
grease. Too much grease will damage the hubs.
5. For Bronco, F-150, F-250 and F-350 with
Install body assembly into vehicle front disc ~rake automatic locking hubs, remove C-ring or snap
hub and rotor by lining up the three legs outSide ring and three thrust washers (spacers). Remove
the hublock bocy witn the three pockets in the the cam assembly and wheel nut retaining key.
cam assembly. Remove wheel retainer (nut).
4. Make sure body assembly is in far enqug~ to see
groove in rotor tube. Install large locknng Into
groove of hub. Be sure lockring is correctly 2-1/2 INCH HEX .
seated. LOCKNUT WRENCH
5. Install cap to body assembly. Install three (F-150, BRONCO WITH
AUTOMATIC LOCKING HUBS)
capscrews and tighten to 4-6 N(ll (35-53 Ib-in). OR 2-3/4 INCH HEX
LOCKNUT WRENCH
(F-250, F-350 WITH
DISASSEMBLY AND ASSEMBLY AUTOMATIC LOCKING HUBS)
Wheel Grease Seal and Bearing, Front

Replacement and Repacking

Hub Locknut Wrench T83T-1197-B
CAUTION: Use of incompatible bearing lubricant

could result in premature lubricant breakdown.
The recommended wheel bearing lubricant is the
lithium-base grease High Temperature 4x4 Front Axle E9807-A
and Wheel Bearing Grease E8TZ-19590-A or
ESA-M1C198-A.

ALL RIGHTS RESERVED
For Bronco and F-150 with manual locking hubs, 7. Remove the retaining nuts of the front wheel
remove C-ring, three thrust washers, the outer spindle (3105). Carefully remove the front wheel
locknut, lockwasher and inner locknut with hub Lugnut spindle from the knuckle studs and halfshaft
Wrench T83T-1197-B. For F-250 and F-350 vehicles (3A329). If necessary, lightly tap the end of the
built after March of 1995 with manual locking hubs, spindle with a rawhide hammer to remove.
remove snap ring, three thrust washers (spacers), the 8. Clean old grease from the needle bearings and
outer locknut, lockwasher, and inner locknut with the bore seal of the front wheel spindle. To
Spanner Locknut Wrench D85T-1197-A. For F-250 replace spindle bearing or inner seal, refer to
and F-350 vehicles built before April, 1995 remove the Spindle RH and LH Shaft and Joint Assembly in
outer locknut, lockwasher and inner locknut with Section 05-03A or Front Drive Axle in Section
Spanner Locknut Wrench D85T-1197-A or equivalent. 05-03B.
HUB LOCKNUT WRENCH 9. For F-150 and Bronco, manual or automatic,
T83T-1197-B inspect spindle outer rolling diaphragm seal
(F-150, BRONCO WITH (RDS). Replace as necessary. To remove spindle
MANUAL LOCKING HUB) RDS, pull seal by hand. If necessary, place front
OR
SPANNER wheel spindle in a vise being careful not to
LOCKNUT WRENCH damage spindle. Pry seal off with screwdriver.
085T-1197 -A For all vehicles, inspect axle shaft seal (Rolling
(F-250, F-350 WITH MANUAL Diaphragm Seal). Replace as necessary. Refer to
LOCKING HUBS) Section 05-03A or 05-03B.
10. Clean any old grease or dirt from these parts and I
replace if signs of excessive wear are noted.

Assembly
1. Using High-Temperature 4x4 Front Axle and
Wheel Bearing Grease E8TZ-19590-A or
ESA-M 1C 198-A, thoroughly lubricate the needle
bearing and coat the front wheel spindles or face
that mates with the seals of the front wheel
spindle.
2. Assemble the front wheel spindle over the
F2370-G halfshaft onto the knuckle studs. Tighten the
retaining nuts to 68-81 N·m (50-60 Ib-ft).
6. Remove the front disc brake hub and rotor. The 3. For F-150 and Bronco only, install outer spindle
front outer wheel bearing will slide out as the hub rolling diaphragm seal (RDS) to the front wheel
is removed. spindle. Seat the RDS by lightly tapping on the
inner sheet metal lip of the seal using a seal
installer with Driver Handle T83T-3132-A and a
hammer to make sure it is seated squarely.

ALL RIGHTS RESERVED
Spindle Roiling Diaphragm Seal - F·150 and Bronco Only
SPINDLE SEAL INSTALLER

3105 (USE WITH
SPINDLE ROLLING DRIVER HANDLE
DIAPHRAGM T83T-3132-A)
SEAL-3254
E9785-A
4. Remove the front inner wheel bearing, wheel hub

DRIVER HANDLE
grease seal (1190) from the front disc brake hub T80T-4000-W
and rotor using Bearing Cup Puller T77F-11 02-A
and Impact Slide Hammer T50T-1 OO-A. Inspect
bearings and replace as necessary.
5. Inspect the bearing cups for pits or cracks. If
necessary, remove with a drift. If new cups are
installed, Install new cones and rollers.
6. Lubricate the bearings with High Temperature
4x4 Front Axle and Wheel Bearing Grease
Specification ESA-M 1C 19B-A. Clean all old
grease from the front disc brake hub and rotor.
Pack the cones and rollers. If a bearing packer is
not available, work as much lubricant as possible
between the rollers and the cages.
7. Position the front inner wheel bearing in the inner
cup and install the new wheel hub grease seal
using a hammer, Driver Handle TBOT-4000-W and
the proper seal installer.
E9808-A
B. Carefully position the hub and disc assembly on

the front wheel spindle.
9. Install the front outer wheel bearing, and wheel
retainer nut or locknuts and lockwashers.
10. Adjust the wheel bearings as described in this
section.
11. For F-150, F-250, F-350 and Bronco with
automatic locking hubs, install cam assembly.
Refer to automatic locking hubs.
12. Install three thrust washers (first metal, second
plastic, third splined) and C-ring or snap ring on
the halfshaft groove for all except F-250 and
F-350 with manual locking hubs built before April
1995.
13. Install tire and wheel (1007) as described in
Section 04-04 in the Body, Chassis manual.

ALL RIGHTS RESERVED
OS-03C-16 Wheel Hubs and Bearings, Front Wheels, 4-Wheel Drive OS-03C-16
14. Install the locking hubs as described in this

section under Removal and Installation. WHEEL RETAINER
15. Remove the safety stands and lower the vehicle. 38459
RETAINING KEY',
ADJUSTMENTS
Front Wheel Bearing, Automatic Locking

Hubs
2. Remove the hublock assembly. Refer to AXLE SHAFT
automatic locking hub removal and installation in 38387
E9810-A
ttlis section.
3. Remove retaining lockring or C-ring and three 7. Install cam assembly.
washers. Remove cam assembly and wheel nut 8. Install three washers in order:
retaining key.
4. Loosen wheel bearing retainer (nut). While • metal washer first, plastic washer second, and
rotating rotor and hub, snug wheel retainer (nut) splined washer last.
to seat wheel bearings. ) 9. Install C-ring or lockring. Align legs of cam
assembly for installation of hub body.
10. Check that the final end play of the front disc
2-1/2 INCH HEX brake hub and rotor on the front wheel spindle is
LOCKNUT WRENCH 0.00-0.11mm (0.000-0.004 inch).
(F-150, BRONCO WITH
AUTOMATIC LOCKING HUBS) 11. Torque required to rotate the front disc brake hub
OR 2-3/4 INCH HEX and rotor is not to exceed 2.3 N·m (20 Ib-in).
LOCKNUT WRENCH
(F-250, F-350 WITH 12. Install hublock. Tighten screws to 4-6 N·m (35-53
AUTOMATIC LOCKING HUBS) Ib-in).
13. Remove safety stands. Lower vehicle.
Front Wheel Bearing, with Manual Locking

Hubs
Tool Number De8crlptlon
T83T-1197-B Hub Locknut Wrench

Remove caliper and brake pads. Refer to Section
06-03 in the Body, Chassis manual.
2. Remove the hublock assembly. Refer to the
manual locking hub removal and installation
E9807-A procedures in this section.
3. For Bronco and all F-Series 4x4, except F-250
5. Back off nut 90 degrees (1 /4 turn). lighten wheel and F-350 built before April 1995, remove C-ring
'" retainer nut to 1.8 N·m (16Ib-in). If necessary,

tighten nut to next hole to allow installation of
etainer key. 4.
and three washers.
Remove the outer locknut with Bronco or Spanner
1E
:.' " . all retaining key into the spindle keyway by
". t.
. rting the short leg into the aligned slot in nut.

Press all the way into position until curved portion
of retaining key is seated into counter bore of
5.
Locknut Wrench D85T-1197-A or equivalent for
F-250 and F-350. Remove the lockwasher.
Using spanner locknut wrench while rotating the
front disc brake hub and rotor ( 1102) back and
wheel retainer (nut). forth, tighten the inner locknut to 68 N·m (50 Ib-ft)
to seat the bearing.
6. Back off the locknut 90 degrees.
.. . ' ~~
0.'
ALL RIGHTS RESERVED
7. NOTE: Hole pattern of lockwasher is offset with 11. For Bronco and all F-Series 4x4, except F-250
keyway to provide half-position settings by and F-350 built before April 1995, install three
flipping washer over to obtain closest hole. washers in order: metal washer first, plastic
Install the lockwasher so the key is positioned in washer second, and splined washer third. Install
the groove of the front wheel spindle (3105). C-ring.
lig~~'en the inner locknut, aligning the pin into the 12. Install the hublocks as described in this section.
nearest lockwasher hole. 13. Remove the safety stands. Lower the vehicle.
J ..... ~ .......
SPECIFICATIONS
Description N·m Lb-Ft Lb·ln
Torx e Head Capscrews 4-6 - 35-53
Retaining Nuts, Front Wheel 68-81 50-60 -
Spindle-to-Halfshaft
Wheel Retainer (Bearing 1..8 - 16
Adjusting Nut) - Automatic
Hublock
Inner Locknut, Front Wheel 68· 50 -
Bearing - Manual Hub Lock
Outer Locknut, Front Wheel 217-278 160-205 -
Bearing - Manual Hub Lock
WHEEL TORQUE SPECIFICATIONS

F-150, Bronco 135 100
(5-Lug Wheel 1/2-20)
F-250-350 190 140
(8-Lug Wheel 9/ 16-18)
NOTE: Torque specifications are for clean, dirt- and

paint-free, dry bolt and nut threads. Never use oil or
grease on studs or nuts.
Part
1 - Pin (Part of Inner Locknut) SPECIAL SERVICE TOOLS/EQUIPMENT
3 1198 Lockwasher
5 T83T-1197-B Hub Locknut Wrench Tool Number/
6 D85T-1197-A Spanner Locknut Wrench Description illustration
A - Tighten to 68 N·m (50 Lb-Ft). T50T-100-A
~
Back Off 90 Degrees. Impact Slide Hammer -
B - Tighten to ~~78 N·m 2-1/2 Lb.
.1 (160-205 Lb~ . > TIOT·'OO-A
T77F-1102-A
8. Install the outer locknut and tighten to ~17-278 Bearing Cup Puller (Use with
N·m (160-205 Ib-ft) using Hub Locknut Wrench Slide Hammer)
T83T-1197-B for F-150 and Bronco or Spanner
Locknut Wrench 085T-1197-A or equivalent for
F-250 and. F-350.
9. Check the final end play of the front wheel T77F-1101-A
spindle. It should be 0.00-0.11mm (0.000-0.004
inch). T80T-4000-W
Driver Handle
10. Torque required to rotate the front disc brake hub
and rotor is not to exceed 2.3 N·m (20 Ib-in). TIOT-4000-W
(Continued)
ALL RIGHTS RESERVED

(Continued)

Tool Number/ Tool Number Description
Description IIlustr.t'on
D85T-1197-A Spanner Locknut Wrench (Dana Model
T83T-1197-B 50 IFS and Model 60 Monobeam Front
Hub Locknut Wrench Drive Axles)
CD TI3T-1117-1
T83T-3132-A
Driver Handle
@~(;?
TIIT-3132·A

ALL RIGHTS RESERVED
07-01A-1
GROUP
TRANSMISSION
.....
CLUTCH PEDAL POSITION (CPP) SWITCH 07-14C-1 TRANSMISSION, MANUAL, M50D •..•••: •. ~~ ••••••...••......07-o3A-1
PARK/NEUTRAL POSITION (PNP) SWITCH •............••07-14B-1 TRANSMISSION, MODEL S5-42 ZF •••.•.....•.....••..••••.•.07-o3B-1
TRANSMISSION, AUTOMATIC, C6 .•...••.•.................•.07-o1B-1 TRANSMISSION RANGE (TR) SENSOR..••••••••...........•07-14A-1
TRANSMISSION, AUTOMATIC, E40D .........•.........•.•.07-o1A-1 TRANSFER CASE, 4X4 SYSTEM, SERVICE ..••....•••.•.•..07-07-1
TRANSMISSION, AUTOMATIC, 4R70W TRANSFER CASE, ELECTRONIC SHIFT....•...•••.......•.07-o7A-1
(AODE-W) ........•.......•.........................................•.07-o1C-1 TRANSFER CASE, MANUAL SHIFT ..•...••......•......••••••07-o7B-1
TRANSMISSION, AUTOMATIC, COOLING 07-o2-1
TRANSMISSION, AUTOMATIC EXTERNAL
CONTROLS ..••....•...••.................•........................•...07-05-1
SECTION 07-01 A Transmission, Automatic, E40D

VEHICLE APPLICATION •......•••. ~ 07-o1A-2 DIAGNOSIS AND TESTING (Cont'd.)
DESCRIPTION AND OPERATION Verification of Condition ••••..••••.•••••.......••.....••••••07-01 A-29
E40D Automatic Transmlssion...........•.......•.........07-o1A-2 IN·VEHICLE SERVICE
Internal Transmission Connector/Harne8s Extension Housing Gasket..•.•...••....••...•..•••••••••07-o1A-105
Diagram ......••.••......................•.•••...••.•.•.••.••••..07-o1A-22 Extension Housing Seal and Bushing ...••••.•......07-Q1A-103
Transmission Electronic Control Fluid Cooler Llnes..•....•.......•..•••••.•••..•.•••••........07-Q1A-117
System .....•...........•......•...•.......•••..•••..............07-01A-10 Main Controi Valve Body •••••••••••••.••••..••••••••••.•••07-o1A-106
Transmission Range Selector and Shift Manual Lever Seal ...............•.•..•...•••.•..••••..•.....07-Q1A-113
Patterns ••....•...•••...•.....••••••••...........................07-o1A-10 Parking Mechanism ....••••...........•..•..•••••..•........07-o1A-123
Transmission, Disassembled View ••••.•...•.............07-01A-5 REMOVAL
DIAGNOSIS AND TESTING Transmission •••.................•••••.••...•.•..••••.......... ~07 -01 A-124
After On-Board Diagnostics .. ~ ....•.....•••...............07-01A-64 Transmission Fluid Draln.and Fill
Before Pinpoint Tests •.........••.••••....••....•••.......07-o1A-64 Procedure .......•...•.••.•....•......•...••....•••......••••.07-01 A-123
Air Pressure Tests ........••.••.••.............••............07-01A-101 DISASSEMBLY
Diagnosis by Symptom Routlnes •••.•.....•.••...••.....07-o1A-29 Transmission ......••.•..•.•.•..............•...•.•••••••.......07-01 A-128
Diagnosis by Symptom Index ••.••....•••..•.•••••....07-o1A-30 DISASSEMBLY AND ASSEMBLY OF
Diagnosis Flow Chart.•...........•...•..............•••......07-o1A-23 SUBASSEMBLIES -
Diagnostic Strategy•...•.••..•••••....•.............•••••.•...07-o1A-22 Center Support...•..•••••.....••••.....•..••••.•.•.•..•...•••.07-o1A-170
Line Pressure Test •...•...•.•••••..•••.•••...••............•...07-o1A-97 Coast Clutch•••••..•..•......••.....•.....•.••••...••••..•...•••07-o1A-156
Torque Converter Drainback Test ••.•.•.............07-o1A-98 Direct Clutch •.•...•.....•..•.........•....••..•.•••••••........07-01A-172
On-Board Diagnostic Quick Tests ••••..........•••.....07-o1A-59 Extension Housing ....••.•........•..•..•..............•.•••07-o1A-188
On-Board Diagnostic Trodble Code Description Forward Clutch..••...••••••••.•...........•...•••..•..•.••••..07-Q1A-179
Chart .••.•..•....••......•.•...••••••...•........•.......•........07-o1A-65 Forward Hub and Ring Gear ....•.•....••..........•...••07-o1A-171
Pinpoint Tests .•.............•.•••••.............................07-01A-75 Forward Planet Assembly •••.•••.•••••.....•..•.....••...07-Q1A-185
Preliminary Inspection ....••.•...•...........................07-01 A-23 Front and Rear Case Bushings ••••.•.•••..••••••.......07-o1A-143
Required Equlpment ..•...•...•.•..•....•••••••••.............07-o1A-22 Input Shell •••......•••••....•.•••....•.......••..•••••...••••••••07-Q1A-186
Rotunda Transmission Tester ...•.•••••••....•......••...07-o1A-69 Intermediate Brake Drum.....•.......••...••••......•.•••07-Q1A-172
Preliminary Set-Up .•..•.••...................•••.•......07-01 A·72 Intermediate/ Overdrive Cylinder
Transmission Tester Instructions.........•••.•......07-01A-70 Assembly ...........•.•••••••.....•....•...............••..•••07-o1A-165
Transmission Tester Use •...........•..............•....07-o1A-70 Low One·Way Clutch ..........•.••••••....•.•.•.••••.....•..07-o1A-188
Shift Point Tests ........•............•.....••.•...............07-01A-100 Main Control Valve Body •.....•••••.......•••••••••..•.•..07-Q1A-146··
Shift Solenoid Failure Mode Charts ........•••••••••...07-01A-77 011 Pump Assembly .....•.....••••.•...•••••••••••.••••••.•.•07-Q1A-149
Solenoid Operation Chart ........................•.••.•....07-o1A-76 Output Shaft •..•.....•......•......•........••..•.••••••...•••..07-o1A-185
Stall Speed Test •••...•••....•.••...............................07-o1A-99 Overdrive Ring Gear and Center Shaft....•..•...•••07-o1A-160
Torque Converter Clutch Test ........•.................07-o1A-100 Reverse Clutch ••..........•.•..•..••.....••••...••••••••..•••.07-o1A·188
Transmission Drive Cycle Test •••••..•••.........••.••...07-o1A-64 Reverse Clutch Piston•••....••...••••..••................••07-o1A-190
Transmission Range (TR) Sensor Testing - Reverse Planet Assembly •...••••••••.••••.••••••..•.••..07-o1A·188
Enhancement.•.......•....•...........•••••...•.....••.•••...07-01A-74 Torque Converter Checks .................•••.•.••..•.•..07-o1A-190
ALL RIGHTS RESERVED
07-01A-2 Transmission, Automatic, E40D 07-01A-2
SECTION 07-01 A Transmission, Automatic, E40D

DISASSEMBLY AND ASSEMBLY OF CLEANING AND INSPECTION (Cont'd.)
SUBASSEMBLIES (Cont'd.) Planet Assemblies 07-01 A-219
One-Way Clutch Check ••.••..........•........••..•.•..07-01 A-191 Thrust Bearings ..............•.....•.....•.....•....••.....•..07-01 A-219
ASSEMBLY Torque Converter .......................•.................•..07-o1A-220
Transmission .•........•........................................07-01 A-193 Transmission 07-01 A-218
INSTALLATION Transmission Cooler and Lines, Back Flushing
Transmission ........••...•••...•••.••..•.......................07-01A-214 and Cleaning 07-01A-218
CLEANING AND INSPECTION Transmission Fluid Cooler Tube
Case .•••.•...............•..•.....••.......•.....•.....•••.........07-o1A-219 Leakage....................................................•..07-01 A-220
Converter and 011 Cooler ....•••..•••......•••............07-o1A-218 SPECIFICATIONS
Electrical Connectors•............•....•......•....•.......07-o1A-219 Automatic Transmission Refill
Forward, Direct, Intermediate, Overdrive, Capacity 07-o1A-220
Coast and Reverse Clutches •..•...••................07-o1A-219 Clutch Plates .....•.............................................07-01A-220
Main Control Valve Body ............•.....................07-o1A-218 Torque Specifications 07-01 A-221
One-Way Clutch •...••.•...•••......•..........................O7-01A-219 SPECIAL SERVICE TOOLS/EQUIPMENT 07-01A-222
Output Shaft ••.•••••••••..•••...••.••..•••...•.•••...••.•.••....07-o1A-219
VEHICLE APPLICATION The application of the piston plate effectively replaces

the hydraulic coupling between the converter cover
All F-Series and Bronco with E40D Automatic and the turbine with a mechanical coupling between
Transmission the converter cover and the turbine hub. This
mechanical coupling helps improve fuel economy and
wide-open throttle performance by eliminating
DESCRIPTION AND OPERATION converter slip.
Transmission shift selection and torque converter
E40D Automatic Transmission clutch operation are controlled by the PCM. They are
calibrated to provide the optimal transmission state.
The E40D transmission is a fully automatic,
This state is commanded to the transmission solenoid
electronically controlled, four-speed unit with a torque
body.
converter clutch. The main operating components of
the E40D transmission include a torque converter An identification tag is located on the left side of the
clutch, six multiple-disc friction clutches, one band, transmission case, rearward of the"Transmission
two sprag one-way clutches and a roller one-way Range (TR) sensor.
clutch which provide for the desired function of three In the 0 range, automatic operation of all four gears is
planetary gear sets. possible. The transmission control switch, located on
Transmission gear selection in the €) range and the vehicle's shift lever disables overdrive operation
converter clutch operation is controlled by the EEC-IV and enables automatic operation through the first
control system. Operating conditions are relayed to three gears. Whenever the ignition switch is turned on,
powertrain control module (PCM)( 12A650) by various the vehicle will automatically provide overdrive
sensors throughout the vehicle. The powertrain operation regardless of the switch position the last
control module compares these conditions with time the vehicle was running.
electronically stored parameters and logically Manual gear selection is available in the 1 and 2 range.
determines how the transmission should operate. Second gear is commanded when the gearshift
A torque converter (7902) couples the engine to the selector lever is in the 2 range and when downshifted
transmission gearset via the input shaft (7017) and the into the 1 range at speeds above approximately 56
torque converter impeller hub. The impeller hub km / h (35 mph) (for diesel 48 km / h l30 mph]). First
provides engine rpm to the positive displacement gear is commanded in the 1 range at start-ups and
pump. The flow from the pump is proportional to engine when downshifted into 1 range below approximately
rpm, and excess pump capacity is exhausted back to 56 km / h (35 mph) (for diesel 48 km / h l30.'mph]). Any
the pump inlet. reference to Intermediate Brake Drum or Direct Clutch
Cylinder are one and the same.
The input shaft transfers power into the transmission
gearset. The power input is controlled by the
application of the torque converter clutch, which is
scheduled through the powertrain control module.
ALL RIGHTS RESERVED
An identification tag is located on the left side of the

transmission case, rearward of the Transmission ASSEMBLY PART TRANSMISSION
Range (TR) sensor. NUMBER PREFIX MODEL
AND SU~UP_BB \
BB O PRA-OA12
00088894
SO 4C20
11
I1I11I11111111111111 I1IIII1 I
5102
BUILD DATE
(YEAR, MONTH SERIAL
AND DAY)
BUILD DATE CODES
YEAR CODE MONTH CODE
1988 - 8 JAN. - A
1989 - 9 FEB. - B
1990 - 0 MAR.- C
1991 - 1 APR. - D
1992 - 2 MAY. - E
1993 - 3 JUN. - F
1994 - 4 JUL. - G
1995 - 5 AUG. - H
1996 - 6 SEP. - J
1997 - 7 OCT. - K
NOV. - L
DEC. - M
D9250-E
E40D Automatic Transmission
D9279-D

ALL RIGHTS RESERVED
Part Part
1 - Torque Converter Clutch 6 7A441 Parking Pawl
(Part of 7902) 7 7F293 Transmission Range (TR)
2 7902 Torque Converter Sensor
3 7B446 Planet Gear Overdrive 8 7C493 Manual Control Lever Shaft
Carrier 9 - Line Pressure Tap
4 7A398 Forward Planet (Part of 7005)
5 70006 Reverse Planet 10 - Shift Linkage Boss
(Part of 7005)
(Continued)

ALL RIGHTS RESERVED
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ALL RIGHTS RESERVED
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;1 D14296-A
en
Part Part
1 7902 Torque Converter 39 78066 Overdrive Clutch Pressure
2 87650-S2 Converter Drain Plug, Plate
1/8In.-27 40 78164 Overdrive Clutch Internal
3 7017 Input Shaft Spline Plate - Friction
4 7L323 Front Pump Support Seal 41 78442 Overdrive Clutch External
Spline Plate - Steel
5 7A248 Front Oil Pump Seal
42 7A527 Overdrive Clutch Piston
6 78258 Converter Hub 8ushing Return Spring Retainer
7 70441 Square Cut Front Oil Pump 43 78070 Overdrive Clutch Piston
Seal Return Spring
8 N805260-S Pump 80lt (9 Req'd) 44 7A262 Overdrive Clutch Piston
M8-1.25x65mm
45 7A548 Overdrive Clutch Piston
9 7G379 Washer (9 Req'd) Outer Seal
10 7A103 Front Oil Pump Assembly 46 7F225 Overdrive Clutch Piston Inner
11 70014 Pump Thrust Washer (No.1) Seal
12 7E486 Overdrive Sun Gear Thrust 47 70483 Intermediate / Overdrive
8earing (No. 2A) Cylinder Retaining Ring
13 7A136 Oil Pump Gasket 48 7Z059 801t-
14 7G402 Coast Clutch Seal Intermediate / Overdrive
15 7G387 Coast Clutch Cylinder Cylinder Hydraulic Feed
16 7A548 Coast Clutch Piston Inner (1 Req'd) M10-1.5x24mm
Seal 49 7G384 Intermediate / Overdrive
17 7A548 Coast Clutch Piston Outer Cylinder
Seal 50 7F225 Intermediate Clutch Piston
18 7A262 Coast Clutch Piston Inner Seal
19 7N519 Coast Clutch Piston Apply 51 7E005 Intermediate Clutch Piston
Ring 52 7F224 Intermediate Clutch Piston
20 78070 Coast Clutch Piston Return Outer Seal
Spring 53 78070 Intermediate Clutch Piston
21 7A527 Coast Clutch Return Spring Return Spring
Retaining Ring 54 7Z059 80lt - Center Support
22 78164 Coast Clutch Internal Spline Hydraulic Feed (2 Req'd)
Plate - Friction M 12-1.75x31mm
23 78442 Coast Clutch External Spline 55 7A130 Center Sl;Jpport Assembly
Plate - Steel 56 7L326 Center Support Thrust
24 78066 Coast Clutch Pressure Plate Washer (No.6)
25 70483 Coast Clutch Pressure Plate 57 70025 Direct Clutch Cast Iron Seal
Retaining Ring Rings
(Selective Fit) 58 78066 Intermediate Clutch
26 70063 Overdrive Sun Gear Pressure Plate - Front
27 377155-S Retaining Ring - Large 59 78164 Intermediate Clutch Internal
Spline Plate - Friction
28 377300-S Retaining Ring
60 78442 Intermediate Clutch External
29 377135-5 Retaining Ring - Small Spline Plate - Steel
30 7A089 Overdrive One-Way Clutch 61 78066 Intermediate Clutch
Assembly (Serviced in Kits Pressure Plate - ~ear
Only)
62 70028 Servo Piston Spring
31 7L339 Overdrive Overrunning
Clutch Washer (No.3) 63 70021 Intermediate 8and Servo
Piston
32 78446 Planet Gear Overdrive
Carrier 64 78264 Intermediate 8and Servo
Retainer
33 7F240 Overdrive Planet Thrust
Bearing Assembly (No.4) 65 7381 Intermediate Servo Piston
Retaining Ring
34 7A153 Overdrive Ring Gear
66 70034 Intermediate 8and
35 7A658 Overdrive Center Shaft
67 7A089 Intermediate One Way
36 70483 Overdrive Clutch Pressure Clutch (Serviced in Kits
Plate Retainer Snap Ring Only)
37 7G375 Retaining Ring 68 7G401 Intermediate One-Way
38 7G178 Overdrive Cent.er Shaft Clutch Thrust Washer (No.7)
Thrust 8earing Assembly 69 70044 Intermediate 8rake Drum
(No.5)
(Continued)
(Continued)
1995 F-150. F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain July 1994
ALL RIGHTS RESERVED
07·01A·7 Transmission, Automatic, E40D 07·01A·7
Part Part
70 7A548 Direct Clutch Piston Inner 102 70234 Forward Clutch Thrust
Seal Bearing (No. 9B)
71 7A548 Direct Clutch Piston Outer 103 70063 Forward / Reverse Sun Gear
Seal 104 70064 Input Shell
72 7A262 Direct Clutch Piston 105 70066 Input Shell Thrust Washer
73 7F235 Direct Clutch Return Spring 106 377300-S Retaining Ring
Assembly 107 70483 Reverse Clutch Pressure
74 7C122 Direct Clutch Return Spring Plate Retaining Ring
Retaining Ring 108 7B066 Reverse Clutch Pressure
75 7C096 Intermediate Brake Drum Plate
Thrust Washer (No.8) '109 7B442 Reverse Clutch External
76 7B164 Direct Clutch Internal Spline Spline Plate - Steel
Plate - Friction 110 7B164 Reverse Clutch Internal
77 7B442 Direct Clutch External Spline Spline Plate - Friction
Plate - Steel 111 377155-S Reverse Planet Retaining
78 7B066 Direct Clutch Pressure Plate Ring
79 377126-S Direct Clutch Pressure Plate 112 7A166 Front-Reverse Planet Thrust
Retaining Ring (Selective Washer (No. 10B)
Fit) 113 70006 Reverse Planet Assembly
80 70019 Forward Clutch Cylinder 114 7A166 Rear-Reverse Planet Thrust
Seal Washer (No. 11)
81 7F374 Forward Clutch Needle 115 387031-S Output Shaft Retaining Ring
Bearing (No. 8B) (1-1/2 In. Oia.)
82 7A360 Forward Clutch Cylinder 116 7A153 Output Shaft Ring Gear
Assembly
117 70164 Output Shaft Hub and Race
83 7A548 Forward Clutch Piston Inner (Serviced in Kits Only)
Seal
84 7A548 Forward Clutch Piston Outer
Seal 119 7B067 Reverse Clutch Hub
Assembly
85 7A262 Forward Clutch Piston
Assembly 120 7A089 Low One-Way Clutch
Assembly (Serviced in Kits
86 70256 Forward Clutch Piston Apply Only)
Ring
121 70422 Output Shaft Hub Thrust
87 7B070 Forward Clutch Piston Washer (No. 12)
Return Spring
122 70406 Reverse Clutch Return
88 377127-S Forward Clutch Piston Spring Assembly
Return Spring Retaining Ring
123 70404 Reverse Clutch Piston Inner
89 7B066 Forward Clutch Pressure Seal
Plate - Bottom
124 70403 Reverse Clutch Piston Outer
90 7B070 Forward Clutch Pressure Seal
Spring
125 70402 Reverse Clutch Piston
91 7B164 Forward Clutch Internal
Spline Plate - Friction 126 7025 Front Case Bushing
Forward Clutch External 127 7005 Case
92 7B442
Spline Plate - Steel 128 7034 Vent
93 7B066 Forward Clutch Pressure 129 70273 Oil Tube Inlet Connector
Plate -Top 130 N605770-S36 Heat Shield Bolt
94 377127-S Forward Clutch Pressure (2 Req'd) M6-1.0x12mm
Plate Retaining Ring 131 7A434 Transmission Heat Shield
(Selective Fit) 132 70174 Converter Drain Back Check
95 70090 Forward Clutch Hub Thrust Valve Assembly - Rear
Washer (No. 8C) 133 7025 Rear Case Bushing
96 377132-S Forward Hub Retaining Ring . 134 70167 Bolts (5 Req'd) 5/16In.-24
97 7B067 Forward Hub 135 7B368 Output Shaft Thrust Washer
98 70392 Forward Ring Gear (No. 13)
99 70234 Forward Clutch Thrust 136 7A233 Park Gear
Bearing Assembly (No. 9A) 137 7060 Output Shaft - (4x2)
100 7A166 Forward Planet Assembly 138 7086 Extension Housing Gasket
Thrust Washer (No. 10A) (4x4)
101 7A398 Forward Planet Assembly 139 7A039 Extension Housing

ALL RIGHTS RESERVED
Part Part
140 N605803-S36 Extension Bolt (Top) 170 N800287-S36 Inner Manual Valve Detent
(7 Req'd) M10-1.5x40mm Lever Nut, M14-1.5 Hex
141 7H102 Wiring Bracket 171 N805503-S Bolt, Hex Flange Head
(Not Serviced) M6-1.0x15.2mm
142 N605802-S36 Extension Bolt (4x2 Bottom) 172 7E332 Manual Valve Detent Lever
(2 Req'd) M10-1.5x35mm Spring
143 7A034 Extension Housing Bushing 173 7N171 Test Port Hex-Head Plug
(4x2) 1/8-27x.62
144 7052 Oil Seal (4x2) 174 N805330-S Stud (4 Req'd)
145 7H183 Extension Housing Plug M6-1.0x61.25mm
Assembly 175 7N171 Converter Housing Access
146 57621-S2 Screw and Washer Plug
Assembly 1/4-20x.62 177 7E195 Rubber Check Ball
147 7060 Output Shaft - (4x4) (9 Req'd, 2 in Main Control)
148 7A039 Extension Housing (4x4) and 353081-S Steel EPC Check Ball
Super Duty 178 N805331-S Stud, M6-1.0x79mm
149 N606569-S36 Extension Bolt (Super Duty 179 70017 Electronic Pressure Control
and 4x4 Bottom) (EPC) Blow-Off Spring
(2 Req'd) M10-1.5x90mm 180 353351-S EPC Blow-Off Ball
150 7A020 Fluid Level Indicator 181 7C155 Separating Plate to Case
151 7A228 Oil Filler Tube Gasket
152 87034-S94 Filler Tube O-Ring 182 7A008 Valve Body Separating Plate
153 7A160 Lube Oil Inlet Short Tube 183 70100 Main Control to Separating
154 N805232-S Bolt and Washer Assembly Gasket
(2 Req'd) M8-1.25x23.8mm 184 7G308 Solenoid Screen Assembly
155 70419 Parking Rod Guide Plate 185 7A100 Main Control Valve Body
156 70070 Parking Pawl Return Spring 186 7F282 Separator Plate Reinforcing
157 7A441 Parking Pawl Plate (Not Serviced)
158 70071 Parking Pawl Shaft 187 N805503-S Bolt (3 Req'd)
M6-1.0x15.2mm
159 N805261-S191 Bolt, M8-1.25x25.9mm
188 7G391 Solenoid Body Assembly
160 7G101 Parking Pawl Abutment
189 N805326-S Bolt (18 Req'd)
161 N620482-S2 Outer Manual Control Lever
M6-1.0x42.5mm
Shaft Nut
190 N805329-S Torx@ Head Bolt (9 Req'd)
162 7A256 Manual Control Lever
M6-1.0x40mm
163 N805312-S100 Bolt Assembly (2 Req'd)
191 N805327-S Bolt (7 Req'd) M6-1.0x66mm
M6-1.0x30mm
192 N805328-S Nut (5 Req'd) M6-1.0
164 7F293 Transmission Range (TR)
Sensor 193 7G422 Accumulator Body Assembly
165 7C493 Manual Control Lever Shaft 194 7A191 Oil Pan Gasket
166 7B498 Manual Control Lever Oil 195 7A098 Filter Assembly and Seal
Seal (Serviced in Kits Only)
167 7B210 Manual Lever Shaft 196 7A194 Transmission Oil Pan
Retaining Pin 197 7L027 Oil Pan Magnet
168 7A232 Parking Lever Actuating Rod (Not Serviced)
169 7A115 Manual Valve Detent Lever 198 N605902-S36 Oil Pan Bolt (20 Req'd)
M8-1.25x15mm
(Continued)

ALL RIGHTS RESERVED
E40D Bearings, Bushings and Thrust Washers
8)
®
@
D
®
@
[]
®
012811-8
Part Part
1 7B258 Front Oil UMP Bushing 9 70234 Forward Carrier
2 - Coast Clutch Bushing (Front / Rear) Thrust Bearing
(Part of 7G387) (9A) (9B)
3 7E486 Overdrive Sun Gear 10 70423 Planet Carrier Thrust Washer
(Front / Rear) Thrust Bearing (10) (10B) (11)
(2A) (2B) 11 7025 Front Case Bushing
4 7G128 Overdrive Carrier to Center 12 7B368 Parking Gear Thrust
Shaft Thrust Bearing (4) Washer (13)
5 7G178 Center Shaft to Center 13 7025 Rear Case Bushing
Support Thrust Bearing (5) 14 7A034 Extension Housing Bushing
6 - Intermediate Brake Drum 15 70066 Input Shell Washer (14)
Front Bushing 16 7G178 Output Shaft Hub Rear
(Part of 70044) Thrust Bearing (12)
7 - Intermediate Brake Drum 17 - Forward / Reverse
Rear Bushing (Front / Rear) Sun Gear
(Part of 70044) Bushing (Part of 70063)
8 7F374 Forward Clutch Hub to 18 7F078 Forward Carrier
Center Support Hub Thrust (Front / Rear) Thrust Bearing
Bearing (8B) (9A) (9B)
ALL RIGHTS RESERVED
Part Part
19 391590-S- Cup Plug 24 - Overdrive Sun Gear Bushing
20 70090 Forward Clutch Hub Thrust (Part of 70063)
Washer (8C) 25 7G400 One-Way Clutch to
21 70428 Intermediate Brake Drum Overdrive Carrier Thrust
Thrust Washer (8A) Washer
22 7G401 One Way Clutch to 26 - Front Pump Support Rear
Intermediate Brake Drum Bushing
Thrust Washer (7) 27 70014 Front Pump Support Thrust
23 7L326 Center Support Thrust Washer (1)
Washer (6) 28 - Front Pump Support Front
(Continued)
Bushing (Part of 7A 103)
Transmission Range Selector and Shift (N) Neutral - The transmission is in NEUTRAL, and
Patterns the output shaft is not locked to the case.
The E40D shift lever has six positions indicated in the (€» Overdrive - Normal driving position for most
following order: P, R, N, €), 2, 1. highway driving conditions and maximum economy.
This position provides all automatic shifts including the
Shift Lever Positions application and release of the torque converter clutch.
(€» Drive with Transmission Control Switch
Activated - This position provides all automatic
I p R r~ @ 21 I shifts, including the application and release of the

torque converter clutch, except for the shift to
overdrive. This position can be used when overdrive is
not desired, such as when traveling in
TRANSMISSION hilly / mountainous terrain or when going into a strong
SELECTOR headwind.
INDICATOR (2) Manual Second - Selection of this position at
D1367D-A start-up provides only second gear operation.
(Selection at higher vehicle speed results in temporary
(P) Park - The transmission is in NEUTRAL with the third-gear followed by an automatic downshift to
output shaft (7060) locked. This prevents the vehicle second gear, which provides engine braking.)
from rolling forward or backward. For safety reasons,
(1) Manual First - Selection of this position at
the vehicle parking brake should be used in addition to
start-up provides only low (first gear) operation.
the transmission PARK position. Do not select the
Selection at higher vehicle speed results in a downshift
PARK position until the vehicle comes to a complete
to second gear. An automatic downshift to first gear
stop, because it mechanically locks the output shaft.
will occur once the vehicle speed drops below
The engine may be started in the PARK position. This
approximately 56 km / h (35 mph) (for diesel, 48 km / h
is the only selector position in which the ignition key
[30 mph]). This position is desired for maximum engine
can be removed.
braking when descending steep grades.
(R) Reverse - Enables the vehicle to be operated in
a rearward direction at a reduced gear ratio. There is
no engine braking in reverse.
Transmission Electronic Control System

The following pages provide a brief description of each
of the sensors and actuators used with the E40D
transmission. The function of each of these
components and the associated symptoms and
Diagnostic Trouble Codes (DTCs) are also given.

ALL RIGHTS RESERVED
Component Illustrations
INPUT/OUTPUT
BAROMETRIC THROTTLE ACCELERATOR IDLE VALIDATION POWERTRAIN TRANSMISSION
PRESSURE POSITION PEDAL (AP) SWITCH (IVS)- CONTROL CONTROL
SENSOR (BARO) . (TP) SENSOR SENSOR - 7.3L 01 DIESEL MODULE INDICATOR LAMP
7.3L 01 DIESEL 9B989 7.3L 01 DIESEL (PCM) (TCIL)
MAP/BARO SENSOR
•.
.
.."
. ".'.~ ~
TRANSMISSION
SOLENOID BODY
• SHIFT CONTROL
SOLENOID 1
• SHIFT CONTROL
SOLENOID 2
• ELECTRONIC
PRESSURE
CONTROL
(EPC) SOLENOID
• TORQUE
CONVERTER
AIR CONDITIONING CLUTCH (TCC)
CLUTCH (AlC) SOLENOID
2884 • COAST CLUTCH
SOLENOID
CAMSHAFT POSITION
(CMP) SENSOR -
7.3L 01 DIESEL
BRAKE ON/OFF TRANSMISSION TRANSMISSION 4X4 LOW

(BOO) SWITCH RANGE (TR) FLUID (4X4 L)
13480 SENSOR TEMPERATURE
7A247 (TFT) SENSOR
MASS AIR FLOW ENGINE OIL INTAKE AIR VEHICLE SPEED

PROGRAMMABLE TEMPERATURE
(MAF) SENSOR SPEEDOMETER/ODOMETER TEMPERATURE (IAT) SENSOR (VSS)
12B579 (EOT) SENSOR - SENSOR -7.3L 01 DIESEL (SOME 1995 MODEL
MODULE (PSOM)
7.3L 01 DIESEL YEAR AND MOTORHOME
TRANSMISSIONS) - 9E731
013678-8
1995 F-150, F-250, F~350, Bronco, F-Super Duty Powertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
Powertraln Control Module (PCM) 12A650: Manifold Absolute Pressure (MAP) Sensor -
Gasoline Engines
On vehicles equipped with gasoline engines, the Barometric Pressure (BARO) Sensor - Diesel
operation of the E40D automatic transmission is Engines
controlled by the powertrain control module. Many
input sensors provide information to the powertrain Description: On gasoline engines, the manifold
control module, which then controls the actuators absolute pressure sensor senses atmospheric
which affect transmission operation. pressure to produce an electrical signal. The
frequency of this signal varies with intake manifold
On vehicles equipped with diesel engines, the
pressure. The manifold absolute pressure sensor
operation of the E40D automatic transmission is also
sends this signal to the powertrain control module.
controlled by the powertrain control module.
The powertrain control module uses this signal to
However, some of the input sensors are different.
determine altitude. The powertrain control module
then adjusts the E40D shift schedule and EPC
pressure for the altitude. On diesel engines, the
"..- barometric pressure sensor operates similar to the
@ manifold absolute pressure sensor. It measures
,...-.-
barometric pressure instead of intake manifold
pressure. The powertrain control module uses the
signal from the barometric pressure sensor to
~:;
[2J
c determine the altitude at which the vehicle is
@ operating. The powertrain control module then
~
adjusts the E40D shift schedule and EPC pressure
for the altitude.
------ l@ ~ ~ TEST PIN 46 0 - - SIG

TEST PIN 45 0 - - MAP
RTN~
TEST PIN 26 0 - - VREF
D11825·A
MANIFOLD ABSOLUTE PRESSURE

VEHICLE HARNESS CONNECTOR
D11831-C
Symptoms: Firm shift feel, late shifts at altitude.

Diagnostic Trouble Codes: 126, 128, 129.
ALL RIGHTS RESERVED
Barometric Pressure (BARO) Sensor - 7.3l DI Transmission Control Switch (TCS) and
Diesel Only: Transmission Control Indicator lamp (TCll)
Description: The barometric pressure sensor Description: The Transmission Control Switch is a
operates similar to the manifold absolute pressure momentary contact switch. When the switch is
sensor. It measures barometric pressure instead of pressed, a signal is sent to the powertrain control
intake manifold pressure. The powertrain control module. The powertrain control module then
module uses the signal from the barometric pressure energizes the transmission control indicator lamp and
sensor to determine the altitude at which the vehicle the coast clutch solenoid, applying the coast clutch
is operating. The powertrain control module then to provide engine braking and cancels fourth gear
adjusts the E40D shift schedule and EPC pressure operation. The TCll indicates overdrive cancel mode
for the altitude. activated (lamp on), electronic pressure control
circuit shorted or monitored sensor failure (lamp
76 WAY flashing).
BULKHEAD CONNECTOR
TRANSMISSION
CONTROL
359 SWITCH
*TEST PIN 91 SIG RTN
GY/R HARNESS
CONNECTOR
VREF 351
TEST PIN 90
BRIW
BARO 356 TRANSMISSION
TEST PIN 84 CONTROL SWITCH
DB/LG TCILLED
TEST PIN 32 HARNESS CONNECTOR
TCll . - . LGIW
*TEST PINS LOCATED ON BREAKOUT BOX
ALL HARNESS CONNECTORS VIEWED INTO
MATING SURFACE TOKEYPWR _ RIY - .....OIIH HIIO....- - -__
FUSE PANEL
SENSOR CONNECTOR TEST PIN 41 A . - TILB Tes

TeS ~ TRANSMISSION CONTROL
SWITCH CONNECTOR
(2)351 ~I"""""''-- (1)359
TEST PINS LOCATED ON BREAKOUT BOX.
ALL HARNESS CONNECTORS VIEWED
INTO MATING SURFACE. D12&36-A
(3)356
Sensor: Transmission Control Switch.
D15117-A Symptoms: No overdrive cancel when switch is
cycled.
Symptoms: Firm shift feel, late shifts at altitude. Diagnostic Trouble Codes: 632, P1780, tested
Diagnostic Trouble Codes: P0107, P0108. during Key On Engine Off (KOEO) On-Board
Diagnostic only.
Actuator: Transmission Control Indicator lamp.
Symptoms: Failed on - overdrive cancel mode
always indicated, no flashing for electronic pressure
control circuit shorted. Failed off - overdrive cancel
mode never indicated, no flashing for electronic
pressure control circuit shorted.
Diagnostic Trouble Codes: 631, P1779.

ALL RIGHTS RESERVED
4x4 Low Switch Transmission Fluid Temperature (TFT) Sensor
Description: The low range switch is located on the Description: The transmission fluid temperature
transfer case cover. It provides an indication of when sensor is located on the solenoid body assembly in
the 4x4 transfer case gear system is in the LOW the transmission sump. It is a temperature-sensitive
range. Modifies shift schedule for 4x4L transfer case device called a thermistor. The resistance value of
gear ratio. the transmission fluid temperature sensor will vary
TOUCH DRIVE with temperature change. The powertrain control
4X4 lOW MODULE HARNESS module monitors voltage across the transmission
TEST 0- lB/BK -41t---. CONNECTED fluid temperature sensor to determine the
PIN 12 temperature of the transmission fluid. The powertrain
control module uses this signal to determine whether
a cold start shift schedule is necessary. The cold
start shift schedule lowers shift speeds to allow for
the reduced performance of cold engine operation.
The powertrain control module also uses the
transmission fluid temperature sensor input to adjust
electronic pressure control pressure for temperature
TO KEY effects and inhibit torque converter clutch operation
TEST PIN o---4.....- -.......-~POWER during the warm-up period.
42-4.9l (CALIF) REFERENCE
S.Ol
S.al (CALIF) 4X4 lOW lED TRANSMISSION FLUID
TEMPERATURE SENSOR
4X4 HIGH LED-REFERENCE
D11834-C
Symptoms: Torque converter clutch and stabilized
TEST PIN l"'-__- - - I -__....- ~ shift schedule happens too soon after a cold start.
42-4.9L (CALIF) Codes 68 or 657 indicate transmission fluid
S.Ol temperature exceeds 270 degrees Fahrenheit,
S.al (CALIF) 4X4 lOW LED-REFERENCE results in increased EPC pressure and torque
converter clutch engagement. May flash transmission
control indicator lamp.
D11832-C Diagnostic Trouble Codes: 636,637,638,657,
Symptoms: Failed on - Early shift schedule in 4x2 P0712,P0713,P1711,P1783.
and 4x4H. Failed off - Shifts delayed in 4x4L. If the
4x4 low indicator light fuse is blown, the transmission
will shift according to 4x4 low shift schedule
regardless of transfer case position.
Dla~n~stlc Trouble Codes: .633, P1781.

ALL RIGHTS RESERVED
Transmission Range (TR) Sensor 7A247: Brake On/Off (BOO) Switch 13480:
Description: The powertrain control module sends Description: The Brake On / Off switch tells the
voltage to the Transmission Range (TR) sensor. The powertrain control module when the brakes are
TR sensor incorporates a series of step-down applied. The switch is closed when the brakes are
resistors which act as a voltage divider. The applied and open when they are released. The PCM
powertrain control module monitors this voltage uses this signal to disengage torque converter clutch
which corresponds to the position of the gearshift when brake is applied.
selector lever (P, R, N, €), 2 or 1). The powertrain
control module uses this information to determine the B+
desired gear and electronic pressure control
pressure. The TR sensor is located on the outside of
the transmission at the gearshift selector lever. FUSE
STOPLAMP
SWITCH
TRS TEST PIN 30 TEST PIN 2 e-- BOO
SRTN TEST PIN 46
STOPLAMP
Symptoms: Failed on or not connected - Torque

converter clutch will not engage at less than 1/3
throttle. Failed off - Torque converter clutch will not
disengage when brake is applied.
Diagnostic Trouble Codes: 536, P 1703.
011835-8
Symptoms: Harsh engagements, firm shift feel.
Diagnostic Trouble Codes: 634, 654, 659, 667, 668,
P1706,P0707,P0708,P0705

ALL RIGHTS RESERVED
Air Conditioning Clutch (A/C Clutch) 2884: , Distributor Ignition (01) System
Description: The Air Conditioning Clutch is an Description: On gasoline engines, the profile ignition
electromagnetic clutch that is energized when the pickup sensor sends a signal to the powertrain
clutch cycling A I C pressure cut-off switch closes. control module indicating the engine rpm and the
The A I C pressure cut-off switch is located on the crankshaft position.
suction accumulator-drier. The closing of the A I C
pressure cut-off switch completes the circuit to the
clutch and draws it into engagelTlent with the
compressor driveshaft. Used as an input to determine
electronic pressure control when the air conditioning
clutch is engaged to compensate for the additional
load on the engine. .
D11829-C
Symptoms: Crankshaft position sensor failure,

engine will not run. May flash transmission control
indicator lamp.
Diagnostic Trouble Codes: 211.
Camshaft Position (CMP) Sensor - 7.3L 01 Diesel

Only:
Description: On the 7.3L 01 diesel engines, the CMP

TEST PIN sensor provides engine RPM information to the PCM.
·10" This RPM input is used to determine shift scheduling
D12802-A
and EPC pressure.
Symptoms: Failed on - electronic pressure control
slightly low with A/C off. Failed off - electronic 42 WAY
pressure control slightly high with A/C on. CONNECTOR HARNESS
Diagnostic Trouble Codes: 539, P1460, P1463,
*TEST PIN 65 ~S_IG_R_TN_---II 33 CONNECTOR
P1464.
VREF
TEST PIN 90 ~------II 21 1 - - -......
CMP SIGNAL
TEST PIN 49 £>-------1 39
*TEST PINS LOCATED ON BREAKOUT BOX.

MATING SURFACE.
SENSOR
CONNECTOR
(A)
(B)
(C)
D15118-A
Symptoms: Harsh engagement and shifts, late WOT

upshifts, abnormal torque converter clutch operation.
Diagnostic Trouble Codes: P0340, P0341, P0344

ALL RIGHTS RESERVED
Mass Air Flow (MAF) Sensor 128579: Throttle Position (TP) Sensor 98989:
Description: The mass airflow sensor directly Description: The throttle position sensor is a
measures the mass of air flowing into the engine. The potentiometer that is mounted on the throttle body on
sensor output is a D.C. (analog) signal ranging from gas applications and on the fuel injection pump lever
0.5 volt to 5 volts used by the processor to calculate on diesel applications. The throttle position sensor
injector pulse width. Used as an input to determine detects the position of the throttle plate or lever and
electronic pressure control. sends this information as a voltage signal to the
powertrain control module.
If a malfunction occurs in the throttle position sensor
circuit, the powertrain control module will recognize
TEST PIN 50 e-MAF1 that the throttle position sensor signal is out of
specification. The powertrain control module will then
MAF D
TEST PIN 9 <!>-RTN-C operate the E40D transmission at a higher line
TEST PIN 40@ pressure to prevent transmission damage. This high
TEST PIN 60 @)-~'(j~4.B line pressure causes harsh upshift and engagements.
TEST PIN 37 @-VPWR
TEST PIN 57@
r
-,
A
Used as an input to determine shift scheduling and
electronic pressure control.
MASS AIR FLOW (MAF)
SENSOR VEHICLE HAANESS
CONNECTOR
D10195-A TEST PIN 46 0- SIG RTN
TEST PIN 47 0-- TP
Symptoms: High electronic pressure, firm shifts and TEST P'N 260-VREF
engagements. May flash transmission control
indicator lamp.
THROTILE
Diagnostic Trouble Codes: 157, 158, 159, 184 and POSITION (TP)
185. SENSOR
VEHICLE
HARNESS
CONNECTOR
D11833·A
Symptoms: Harsh engagements, firm shift feel,

abnormal shift schedule, abnormal or no torque
converter clutch operation. May flash transmission
Diagnostic Trouble Codes: 23, 33, 43, 53, 63, 73, (2
digit), 121, 122, 123, 124, 125, 167 (3 digit).

ALL RIGHTS RESERVED
Accelerator Pedal (AP) Sensor - 7.3L DI Diesel Vehicle Speed Sensor (VSS) 9E731:
Only:
Description: The vehicle speed sensor is a variable
Description: The accelerator pedal (AP) sensor is reluctance sensor that sends an AC / frequency signal
mounted on the accelerator pedal on 7.3L 01 diesel to the powertrain control module. The vehicle speed
engines. The AP sensor detects the position of the sensor signal is used by the powertrain control
accelerator pedal and sends this information as a module to calculate vehicle speed in mph. Used as an
voltage signal to the PCM. input in determining shift scheduling and electronic
If a malfunction occurs in the AP sensor circuit, the pressure control.
powertrain control module will recognize that the AP
sensor signal is out of specification. The powertrain
control module will then operate the E400
transmission at a higher line pressure to prevent
transmission damage. This high line pressure causes
harsh upshift and engagements. Used as an input to
determine shift scheduling and electronic pressure
control.
~
VEHICLE
SENSOR , SPEED
76 WAY BULKHEAD
CONNECTOR
CONNECTOR *TEST PIN 6 e--
VSS DIF (-) " SENSOR
TEST PIN 3 0-VSS DIF (+) .. (VSS)
VEHICLE
. HARNESS
CONNECTOR
D10198-A
TEST PIN 89 ... ~-----",
abnormal shift schedule; unexpected downshifts may
occur at closed throttle, abnormal torque converter
clutch operation or torque converter clutch engages
only at wide-open throttle. May flash transmission
*TEST PINS LOCATED ON BREAKOUT BOX control indicator lamp.
MATING SURFACE D15119.A Diagnostic Trouble Codes: 452, P0500.

abnormal shift schedule, abnormal or no torque
converter clutch operation. May flash transmission
Diagnostic Trouble Codes: P0122, P0123

ALL RIGHTS RESERVED
Programmable Speedometer/Odometer Module Solenoid Operation

(PSOM)
Description: The Programmable SOLENOID OFF SOLENOID ON

Speedometer / Odometer Module receives input from
the rear brake anti-lock sensor, which is mounted on
the rear axle differential housing. The PSOM
processes this input signal information and relays it
to the powertrain control module and the speed
control module. This signal tells the powertrain
control module the vehicle speed in miles per hour
(mph). Used as an input in determining shift
scheduling and electronic pressure control.
r-
I
I r
VEHICLE SPEED
SENSOR-9E731
I
(MODEL DEPENDANT)
D13679-A
+
1
I
I
I . ® . Item
Part
Number Description
....--..... I
, PROGRAMMABLE u+H POWERTRAIN
, SPEEDOMETER ~6 CONTROL 1 - Solenoid (Part of
ODOMETER ~ MODULE Transmission Solenoid
~ MODULE ~H 12A650
Body)
17255
2 - Check Ball (Part of Solenoid)
3 - Feed (Blocker)
4 - Feed
REAR SPEED
ANTI-LOCK 5 - Output (to Shift Valves, etc.)
CONTROL
BRAKE MODULE
RABS __
·- _....,.' MODULE
SPEED '
SENSOR
2C190 D11826-C
abnormal shift schedule, unexpected downshifts may
occur at closed throttle, abnormal torque converter
clutch operation or engages only at Wide-Open
Throttle (WOT). May flash transmission control
indicator lamp.
Diagnostic Trouble Codes: 452, P0500.
Transmission Solenoid Body:
Description: The powertrain control module controls

the E40D transmission operation through four on / off TRANSMISSION SOLENOID BODY
solenoids and one Variable Force Solenoid. These 7G391 05992-0
solenoids and transmission fluid temperature sensor
are housed in the transmission solenoid body Part
assembly. All are part of the transmission solenoid Item Number Description
body and are not serviced individually. Additionally,
protection diodes that were on the solenoid body 1 - Shift Solenoid 1
(Part of 7G391)
have been moved to the PCM. Refer to the following
information for the functions of these solenoids. 2 - Shift Solenoid 2
(Part of 7G391)
The four on / off solenoids operate in the following 3 - Electronic Pressure Control
manner. Solenoid (Part of 7G391)
4 - Coast Clutch Solenoid
• When the solenoid is off, the fluid pressure feed is (Part of 7G391)
blocked by a check ball. The check ball is held in 5 - Transmission Fluid
place by the solenoid piston. Temperature Sensor
Location (Part of 7G391)
• When the solenoid is turned on by the PCM, the
6 - Torque Converter Clutch
piston is pulled up, releasing the check ball and Solenoid (Part of 7G391)
allowing fluid pressure to be applied to the check
valves and / or other components controlled by the
solenoid.

ALL RIGHTS RESERVED
Shift Solenoid 2:
TRANSMISSION CONNECTOR PIN ASSIGNMENTS
EEC-IV 50-WAY Symptoms: Improper gear selection depending on

12-WAY CONNECTOR PIN failure mode and manual lever position; refer to the
CONNECTOR DESCRIPTION 4.7L ICALIF)
PIN GAS DIESEL 5.0L
Shift Control Solenoid Application Chart. May flash
5.8L ICALIF) transmission control indicator lamp.
1 VEHICLE POWER (VPWR) 37,57 71,97 37,57 Diagnostic Trouble Codes: 622· , 617· • , 619· •
SHIFT SOLENOID 2 19 1 52
2 (. Output circuit check, generated only by electrical
3 SHIFT SOLENOID 1 52 27 51
TORQUE
condition. • • May also be generated by other
53 28 53
4
CONVERTOR CLUTCH non-electronic related transmission hardware
5
COAST CLUTCH
55 28 55 condition).
SOLENOID
6
TRANSMISSION OIL
Coast Clutch Solenoid
7 42 37 49
TEMPERATURE SENSOR
8
SIGNAL RETURN
46 91 46
The Coast Clutch Solenoid provides coast clutch
(SIG RTN)
control by shifting the coast clutch shift valve. The
9
10
solenoid is activated by pressing the transmission
ELECTRONIC PRESSURE control switch or by selecting the 1 or 2 range with
11 38 91 38
CONTROL the transmission gearshift selector lever. In manual 1
ELECTRONIC PRESSURE 37,57 and 2, the coast clutch is controlled by the solenoid
12 37,57 71,97
CONTROL POWER
and also hydraulically as a fail-safe to ensure engine
braking. In reverse, the coast clutch is controlled
12-WAY CONNECTOR hydraulically and the solenoid is not on. NOTE: On
TRANSMISSION END HARNESS END
certain applications, the coast clutch is controlled by
the PCM in the overdrive position (TCS OFF) in gears
PIN 1
1,2, and 3.
Symptoms: Failed on - Third gear engine braking
with €) range selected. Failed off - No third gear
engine braking in overdrive cancel.
Diagnostic Trouble Codes: 626· , P 1754 • .
• Output circuit check, generated only by electrical
condition.
• • May also be generated by other non-electronic
PIN 7 PIN6 PIN 6 related transmission hardware condition.
NOTE: BOTH VIEWS ARE "LOOKING INTO" Torque Converter Clutch (TCC) Solenoid
THE CONNECTORS MATING ENDS
D11838-C Torque converter clutch solenoid provides torque
converter clutch control by shifting the converter
Shift Solenoids 1 and 2 clutch control valve to apply or release the torque
converter clutch.
Shift solenoids 1 and 2 pro~ide gear selection of first
Symptoms: Failed on - Engine stalls in drive at idle
through fourth gears by controlling the pressure to
low speeds with brake applied or manual 2. Failed off
the three shift valves.
- Converter clutch never engages. May flash
transmission control indicator lamp.
Shift Solenoid 1:
Diagnostic Trouble Codes: 629· , P0743· (. Output
Symptoms: Improper gear selection depending on circuit check, generated only by electrical condition.
failure mode and manual lever position; refer to the • • May also be generated by other non-electronic
Shift Control Solenoid Application Chart. May flash related transmission hardware condition).
Diagnostic Trouble Codes: 621 • , 617· • , 618· • ,
619··,P0750·,P0781··,P0782··,P0783··
(. Output circuit check, generated only by electrical
condition. • • May also be generated by other
non-electronic related transmission hardware
condition).

ALL RIGHTS RESERVED
Electronic Pressure Control (EPC) Solenoid Electronic Pressure Control (EPC) Solenoid (Cont'd)
Description: The Electronic Pressure Control Diagnostic Trouble Codes: 624 * , 625 *, P 1746 * ,
solenoid is a variable force solenoid. The P1747* .
variable-force type solenoid is an electro-hydraulic CAUTION: The electronic pressure control
actuator combining a solenoid and a regulating valve. pressure output from the variable force solenoid is
It supplies electronic pressure control which NOT adjustable. Any modification to the electronic
regulates transmission line pressure and line pressure control solenoid will affect the
modulator pressure. This is done by producing transmission warranty. (* Output circuit check,
resisting forces to the main regulator and the line generated only by electrical condition. * *May also be
modulator circuits. These two pressures control generated by other non-electronic related
clutch application pressures. transmission hardware condition.)
Symptoms: Failed on - Minimum electronic
pressure control pressure (minimum transmission Solenoid Operation Chart
torque capacity). Limit engine torque (partial fuel The following solenoid application chart shows normal
shut-off, heavy misfire). Flashing transmission solenoid operation for given operating modes.
Failed off - Maximum electronic pressure control
pressure, harsh engagements and shifts. May flash
(Continued)
SOLENOID OPERATION CHART

Powertraln Control Torque Converter
Gearshift Selector Module Shift Control Shift Control Clutch Coast Clutch
Lever Position Commanded Gear Solenoid 1 Solenoid 2 Solenoid Solenoid
Park First ON OFF OFF OFF
Reverse First ON OFF OFF OFF
Neutral First ON OFF OFF OFF
a a
{) First ON OFF
a a
{) Second ON ON
a a
{) Third OFF ON
a
{) Fourth OFF OFF OFF
€) First Through Third Gear Only, Shift Solenoid 1, Shift Solenoid 2, and Torque Converter Clutch, Same As
Cancel Overdrive, Coast Clutch Solenoid Always On.
a
Manual 2 Second OFF OFF ON
Manual 1 Second OFF OFF OFF ON
Manual 1 First ON OFF OFF ON
a Powertrain control module controlled.

ALL RIGHTS RESERVED
Internal Transmission Connector/Harness • This Service Manual

Diagram • Transmission Reference Manual
• Powertrain Control/Emission Diagnosis (PC / ED)
Manual
EEC-IV 60-WAY • Oasis Messages
12·WAY CONNECTOR PIN
CONNECTOR DESCRIPTION 4.7L (CALIF)
• Technical Service Bulletins
PIN GAS DIESEL 5.0L
5.8L (CALIF)
• Electrical/Vacuum Trouble Shooting Manual
1 VEHICLE POWER (VPWR) 37,57 71,97
(EVTM)
37,57
2 SHIFT SOLENOID 2 19 1 52 These publications provide the information required
3 SHIFT SOLENOID 1 52 27 51 when diagnosing transmission concerns.
TORQUE
4 53 28 53
CONVERTOR CLUTCH Using the Diagnostic Flow Chart as a guide, follow the
5
COAST CLUTCH
55 28 55 steps as indicated.
SOLENOID
6 Preliminary Inspection
TRANSMISSION OIL
7 42 37
TEMPERATURE SENSOR 49 1. Know and understand the customer's concern.
SIGNAL RETURN
8
(SIG RTN)
46 91 46 2. Verify the concern by operating the vehicle.
9
3. Check the fluid level and condition.
10
11 ELECTRONIC PRESSURE 4. Check for non-factory add-on items.

38 91 38
CONTROL
ELECTRONIC PRESSURE
5. Check shift linkages for proper adjustment.
12 37,57 71,97 37,57
CONTROL POWER
6. Check TSBs and Oasis messages for the
concern.
12-WAY CONNECTOR Diagnostics
TRANSMISSION END HARNESS END 1. Perform On-Board Diagnostic Procedures
PIN 1 (KOEO, KOER).
2. Record all Diagnostic Trouble Codes (DTCs).
3. Repair all non-transmission codes FIRST.
4. Repair all transmission codes SECOND.
5. Erase all continuous codes and attempt to repeat
them.
6. Repair all continuous codes.
PIN 7 PIN 6 PIN 6 PIN 7 7. If ONLY PASS codes, proceed to Diagnosis by
Symptom charts for further information and
NOTE: BOTH VIEWS ARE "LOOKING INTO" diagnosis.
By following the diagnostic sequence the service
D11838-C technician will be able to diagnose and repair the
concern the first time.
Diagnostic Strategy Required Equipment

Troubleshooting an electronically controlled automatic Required equipment necessary to diagnose an E40D
transmission is simplified by using the proven method transmission consists of:
of diagnosis. One of the most important things to • Rotunda Transmission Tester 007-0085C
remember is that there is a definite procedure to
follow. DO NOT TAKE SHORT CUTS OR ASSUME • Rotun~a Super Star II Tester 007-0041B
THAT CRITICAL CHECKS OR ADJUSTMENTS • Rotunda EEC-IV 60-pin Breakout Box 007-00033
HAVE ALREADY BEEN MADE. Follow the
• Rotunda 73 Digital Multimeter 105-00051
procedures as written to avoid missing critical
components or steps. • Rotunda Transmission Range (TR) Sensor Cable
("MLPS" Manual Lever Position Sensor Cable)
To properly diagnose a concern the technician should
007-00086
have the following publications available:

ALL RIGHTS RESERVED
07-01A-23 Transmission, Automatic, E40D 07-01A43
Diagnosis Flow Chart
• Know and understand the customer's concern

• Check fluid level and condition
• Verify the concern by operating vehicle NOTE:
• Check for non-factory installed items and If you find and repair the cause
verify proper installation of the transmission concern at any
• Check shift linkage adjustment in overdrive point in this diagnostic flow chart,
• Check TSS'S and OASIS for vehicle concern "Go to" the last action box.
• Perform -QUICK TEST- both KOEO 8t KOER
• Record all codes
Diagnostic Trouble Codes Pass codes
Go to -Diagnosis by
Repair all hard Diagnostic Trouble codes. symptom·routines of the
Follow pinpoint tests in PC/ED manual* .Transmission Reference
first, then Transmission Reference Manual/this Service Manual
Manual/this Service Manual
NO
NO
Install the Transmission Tester.

Perform static and drive tests
Clear codes and perform drivecycle test with Transmisssion Tester
NO
Repair continuous test memory codes,

Go to PC/ED manual*, Intermittent
follow pinpoint tests in the PC/ED
fault diagnosis section and use
manual· first, then Transmission
EEC-IV Monitor, 8.0.S or SaDS to
Reference Manuallthis Service Manual
diagnose cause of concern in the
processor, vehicle harness or
external inputs (sensors/switches)
Use
" HydrauliclMechanical
NO Routine" to diagnose
and repair concern
YES
• Perform final "Quick Test" to verify

no Diagnostic Trouble Codes are present
* Can be purchased as • Clear memory code
a separate Items. • Return vehicle to customer D12940-B
Preliminary Inspection 2. Validate customer's concern (when does it

The following items must be checked before exist?).
proceeding: a. Upshift
1. Know and understand the customer's concern. b. Downshift

ALL RIGHTS RESERVED
c. Coasting CAUTION: Your vehicle should not be driven if the

d. Engagement fluid level is below the bottom hole on the fluid
level indicator and outside temperature is above
e. Noise/Vibration 10°C (50°F).
If noise/vibration, check for dependencies, When checking fluid at normal operating temperature,
either RPM dependent, vehicle speed the fluid level should be within the crosshatched area
dependent, shift dependent, gear dependent, or "HOT" marked area on the fluid level indicator.
range dependent, or temperature dependent. When the vehicle has not been driven, and outside
3. Vehicle at normal operating temperature. temperature is above 10°C (50°F), the fluid level
should be between the holes or "COLD" marked area
4. Check fluid level and condition. on the fluid level indicator.
5. Visually inspect the vehicle for the following Only Motorcraft MERCON@ Multi-Purpose Automatic
items: Transmission Fluid XT-2-QDX or MERCON@ equivalent
• vehicle modification should be used in all Ford automatic transmissions.
Before adding any fluid, be sure that the correct type
• electronic add-on items will be used.
• leaks Add fluid in .24L (1 / 2-pint) increments through the oil
• proper linkage adjustments filler tube to bring the level to the correct area on the
fluid level indicator. If an overfill occurs, excess fluid
6. Check Technical Service Bulletins and Oasis for
must be removed.
concern information.
7. Perform the complete On-Board Diagnostic Transmission Hot - Operating Temperature
procedures (KOEO, KOER). The automatic transmission should be checked at an
operating temperature of 66°C-77°C (150°F-170°F)
Transmission Fluid Level Check (fluid level indicator hot to touch). The operating
CAUTION: Vehicles equipped with 4x4 temperature may be obtained by driving 24-32 km
applications must have the 4x4 gearshift selector (15-20 miles) of city-type driving with the outside
lever in any position other than neutral. temperature above 10°C (50°F).
NOTE: If the vehicle has been operating for an CAUTION: If vehicle has been operated for an
extended period at high speeds or in city traffic during extended period at high speed, in city traffic, in
hot weather, or pulling a trailer, the vehicle should be hot weather, or vehicle is being used to pull a
turned off for about 30 minutes to allow the oil to cool trailer, the fluid has to cool approximately 30
before checking. minutes after engine has been turned off to
Under normal circumstances, you do not need to obtain an accurate reading.
check the fluid level of the transmission, since the Transmission Cold - Room Temperature
vehicle does not use up transmission fluid. However, if
the transmission is not working properly, for instance, If the transmission is not at an operating temperature
the transmission may slip or shift slowly, or you may of 66°C-77°C (150°F-170°F) and it becomes
notice some sign of fluid leakage, the fluid level should necessary to check the fluid level (such as
be checked. predelivery), the fluid may be checked at room
temperature of 21 ° C-35 ° C (70 ° F-95 ° F) (fluid level
It is preferable to check the transmission fluid level at indicator cool to touch).
normal operating temperature after approximately 32
km (20 miles) of driving. However, if necessary, you Transmission Fluid Indicator Reading
can check the fluid level without having to drive 20 NOTE: The fluid level indication on the fluid level
miles to obtain a normal operating temperature if indicator will be different at operating temperature and
outside temperature is above 10°C (50°F). room temperature. For the correct fluid level reading
With the vehicle on a level surface, start the engine on the fluid level indicator, follow the appropriate
and move the transmission gearshift selector lever instructions stated previously.
through all of the gear ranges allowing sufficient time Fluid level on fluid level indicator should be within the
for each position to engage. Securely engage the cross-hatched area.
transmission gearshift selector lever in the park
position, fully set the parking brake control (2780) and
leave the engine running.
Wipe off the fluid level indicator cap, pull the fluid level
indicator (7A020) out and wipe the indicator end
clean. Put the fluid level indicator back into the oil filler
tube (7A228) and make sure it is fully seated. Pull the
fluid level indicator out and read the fluid level.

ALL RIGHTS RESERVED
Fluid level on the fluid level indicator should read If fluid contamination or transmission failure is
between the holes at room temperature. confirmed by further evidence of coolant or
excessive particles in the transmission oil pan,
the transmission must be disassembled and
completely cleaned and serviced. This includes
cleaning and flushing the torque converter (7902)
and transmission cooling system.
~~FLUID LEVEL AT OPERATING TEMPERATURE
~~--J . 0
66°e-77°C (150 F-170°Fj During disassembly and assembly, all overhaul
checks and adjustments of clearances and end
• FLUID LEVEL AT ROOM TEMPERATURE play must be made.
21°C-35°C (70°F-95°F)
After the transmission has been serviced, all
........... DO NOT DRIVE MARK
08439-8 diagnostic tests and adjustments listed in the
Diagnostic Charts must be completed to make
sure that the problem has been corrected.
High or Low Fluid Level
A fluid level that is too high may cause the fluid to External Sealing
become aerated due to the churning action of the The E40D transmission has the following parts to
rotating parts of the transmission. Aerated fluid will prevent external fluid leakage:
cause erratic control pressure, and the aerated fluid
may be forced from the vent (7034). • Gaskets
A fluid level that is too low will affect transmission • Lip-type seals
operation. Low level may indicate fluid leaks that may • O-ring seals
cause transmission damage.
• Seal rings
Transmission Fluid Condition Check • Seal grommets
1. Make the normal fluid level check as outlined
• Thread sealant
previously under Transmission Fluid Level Check.
2. Observe color and odor of the fluid. It should be
red, not brown or black. Odor may indicate
overheating condition, clutch disc or band failure.
3. Use an absorbent white facial tissue and wipe the
fluid level indicator. Examine the stain for
evidence of solid particles and for engine coolant
signs (gum or varnish on fluid level indicator).
If particles are present in the fluid or there is
evidence of engine coolant or water, the
transmission oil pan (7A 194) must be removed
for further inspection.
ALL RIGHTS RESERVED
External Sealing - E40D
D13680-A
Part Part
1 7902 Converter Assembly 13 7005 Case
2 87650-S2 Converter Drain Plug 14 7034 Vent Assembly
3 7L323 Front Pump Seal 15 70273 Front Oil Cooler Tube
4 7A248 Front Pump Seal Assembly Connector Assembly
5 70441 Front Pump Square Cut 0.0. 16 70174 Rear Oil Cooler Tube
Seal Connector Assembly
6 N805260-S Bolt and Washer Assembly 17 7086 Extension Housing Gasket
7 7G379 Washers 18 7A039 Extension Housing (4x2)
8 7A136 Front Oil Pump Gasket 19 7052 Extension Housing Seal
9 7A020 Transmission Fluid Level 20 7A039 Extension Housing (4x4)
Indicator 21 7H183 Extension Housing Plug
10 7A228 Oil Filler Tube Assembly 22 7B498 Manual Lever Fluid Seal
11 391308-2 Tube Seal I'
23 7G391 Solenoid Valve Body
12 7N463 Short Oil Inlet Tube Assembly
Assembly 24 7A191 Oil Pan Gasket
(Continued) 25 7A264 Oil Pan
Transmission Fluid Leakage Checks Check the transmission fluid filler tube connection at
Leakage at the transmission oil pan to case gasket the transmission case. If leakage is found here, install
(7A 191) often can be stopped by tightening the a new lube oil inlet short tube (7A 160).
attaching bolts to 14-16 N·m (10-12 Ib-ft). If
necessary, replace the oil pan to case gasket.
If leakage is found by the solenoid body connector,
refer to Main Control Valve Body Removal and
Installation procedure in this section. Replace O-ring
on the connector snout of the solenoid body assembly.
ALL RIGHTS RESERVED
Check the transmission oil lines and fittings between Torque Converter Area Leak Points
the transmission and the transmission fluid cooler
(7A095) in the radiator tank for looseness, wear, or
damage. If leakage cannot be stopped by tightening an
oil line tube nut, replace the damaged parts. When fluid
is found to be leaking between the case and the cooler
line fitting, tighten the fitting to maximum specification.
Do not try to stop the fluid leak by increasing the
torque beyond specification. This may cause
damage to the case threads. If the leak continues,
replace the cooler line fitting and tighten to
specification. The same procedure should be followed
for fluid leaks between the radiator cooler and cooler
line fittings.
Check the engine coolant in the radiator (8005). If
transmission fluid is present in the coolant, the
transmission fluid cooler in the radiator is probably
leaking.
The transmission fluid cooler can be further checked
for leaks by disconnecting the lines from the cooler
fittings and applying no more than 345 kPa (50 psi) air
pressure to the fittings. Remove the radiator cap
(8100) to relieve the pressure buildup at the exterior
09131-0
of the oil cooler tank. If the transmission fluid cooler is
leaking and / or will not hold pressure, replace the
transmission fluid cooler. Part
If leakage is found at the manual control lever shaft
(7C493), replace the seal. 1 - Crankshaft Leak
2 - Converter Impeller Seal
When a converter drain plug leaks, remove the drain Leak
plug. Install new drain plug. lighten to 24-27 N·m -
3 Pump Bolt Leak or Pump
(18-20Ib-ft). Seal Leak
Check for fluid leaking from the end of extension 4 - Weld Leaks
housing (7A039). Leakage may result from damaged 5 - Plug Leaks
oil seal (7052), missing garter spring or worn 6 - Crankshaft Leak
extension bushing or damaged speedometer plug.
Replace seal assembly and/or bushing as necessary. 1. Fluid leaking by the torque converter impeller hub
Inspect the plugs for leakage. Ensure they are seal lip will tend to move along the converter
tightened to 8-16 N·m (6-12Ib-ft). If tightening does impeller hub and onto the back of the impeller
not stop the leak, replace the plug. housing. Except in the case of a total seal failure,
fluid leakage by the lip of the seal will be
Using the old oil cooler tube as a guide, bend the new deposited on the inside of the converter housing
oil cooler tube as required. Add the necessary fittings only, near the outside diameter of the converter
and install the oil cooler tube. housing.
After the fittings have been tightened, add fluid as 2. Fluid leakage by the outside diameter of the
needed and check for fluid leaks. converter hub seal and the case will follow the
Fluid Leakage in Torque Converter Area same path which the leaks by the inside diameter
of the seal follow.
In diagnosing and correcting fluid leaks in the torque
converter area, use the following procedures to locate 3. Fluid leakage from the torque converter to the
the exact cause of the leakage. Leakage at the front flywheel stud weld will appear at the outer
of the transmission as evidenced by fluid around the diameter of the torque converter on the back face
converter housing, may have several sources. By of the flywheel (6375), and in the converter
careful observation it is possible, in many instances, to housing only near the flywheel. If a
pinpoint the source of the leak before removing the converter-to-flywheel stud leak is suspected,
transmission from the vehicle. The paths which the remove torque converter and pressure check as
fluid can take to reach the bottom of the converter outlined.
housing are as follows: 4. Fluid leakage from the pump will flow down the
back of the converter housing. Leakage may be
from loose or missing pump bolts, torn or
damaged pump-to-case gasket and / or a worn
pump bushing.
ALL RIGHTS RESERVED
5. Engine oil leaks are sometimes improperly Leak Check Test with Black Light
diagnosed as transmission pump seal leaks. The Oil soluble aniline or fluorescent dyes premixed at the
following areas of possible leakage should also rate of 2.5ml (1/2 teaspoon) of dye powder to 0.24L
be checked to determine if engine oil leakage is (1 /2 pint) of automatic transmission fluid have proven
causing the problem. helpful in locating the source of fluid leakage. Such
a. Leakage at the valve cover may allow engine dyes may be used to determine whether an engine
oil to flow over the converter housing or seep fluid or transmission fluid leak is present, or if the fluid
down between the converter housing and in the transmission oil cooler hose (7B093) leaks into
block causing oil to be present in or at the the engine coolant system. An ultraviolet light must be
bottom of the converter housing. used to detect the fluorescent dye solution.
b. Oil plug leaks will allow oil to flow down the Transmission Fluid Cooler Flow Check
rear face of the block to the converter
housing. NOTE: The transmission linkage / cable adjustment,
fluid level, and line pressure must be within
c. Leakage at the crankshaft seal will work specification before performing this test. Refer to
back to the flywheel, and then into the service procedures as outlined.
converter housing.
1. Remove fluid level indicator from oil filler tube.
6. The following procedures should be used to
determine the cause of the leakage before 2. Place funnel in oil filler tube.
service is made. 3. Raise vehicle on hoist and position suitable safety
a. Remove the fluid level indicator and note the stands under vehicle.
color of the fluid. Original factory fill fluid is 4. Remove cooler return line (rear fitting) from fitting
dyed red to aid in determining if leakage is on transmission case. Refer to Oil Cooler Line
from the engine or transmission. Unless a Removal and Installation procedure in this
considerable amount of makeup fluid has section.
been added or the fluid has been changed, 5. Connect one end of a hose to the cooler return
the red color should assist in pinpointing the line and route the other end of the hose up to a
leak. point where it can be inserted into the funnel at
b. Remove the converter housing cover. Clean the oil filler tube.
off any fluid from the top and bottom of the 6. Remove safety stands and lower vehicle. Insert
converter housing, front of the transmission end of hose into funnel.
case, and rear face of the engine and pan.
Clean the converter area by washing with 7. Start engine and run at idle with transmission in
suitable nonflammable solvent, and blow dry neutral range.
with compressed air. 8. When oil flowing from hose is all liquid, an
c. Wash out converter housing and the front of adequate amount of fluid should be observed,
the flywheel. The converter housing may be approximately 1 /2 quart delivered in 30
washed out using clean solvent and a seconds. If adequate flow is observed, test is
squirt-type oil can. Blow all washed areas dry completed.
with compressed air. 9. If the flow is not adequate, stop engine.
d. Start and run the engine until the transmission Disconnect hose from cooler return line and
reaches its normal operating temperature. connect it to converter-out line fitting (front fitting)
Observe the back of the block and top of the on transmission case.
converter housing for evidence of fluid 10. Repeat Steps 7 and 8. If flow is now adequate,
leakage. Raise the vehicle on a hoist and refer to appropriate section for diagnosis of
position suitable safety stands under vehicle. transmission fluid cooler. If flow is not adequate,
Run the engine at fast idle, then at engine idle, service pump and / or converter assembly.
occasionally shifting to the drive and reverse
ranges to increase pressure within the Transmission Fluid Cooler Tube Leakage
transmission. Observe the front of the When fluid leakage is found at the transmission fluid
flywheel, back of the block (in as far as cooler, the transmission fluid cooler must be replaced.
possible), and inside the converter housing Refer to Section 03-03.
and front of the transmission case. Run the
engine until fluid leakage is evident and the When transmission fluid cooler steel lines must be
probable source of leakage can be replaced, each replacement line must be fabricated
determined. from the same size inside diameter and length steel
line as the original line.
7. When a converter drainplug leaks, remove drain
plug. Install new drain plug. Tighten to 24-27 N·m Using the old line as a guide, bend the new line as
(17-19Ib-ft). required. Add the necessary fittings, and install the
line.
After the fittings have been tightened, chec:, and add
fluid as necessary. Check for fluid leaks.

ALL RIGHTS RESERVED
Verification of Condition • These items, if not installed properly, will affect

This section provides information which must be used powertrain control module or transmission
in both determining the actual cause of customer function. Pay particular attention to add-on
concerns and performing the appropriate service wiring splices in the powertrain control module
procedures. (PCM)( 12A650) harness or transmission
wiring harness, abnormal tire size or axle ratio
The following procedures must be used when verifying; changes.
customer concerns for E40D transmission:
• After a road test, with the vehicle warm and
NOTE: The Rotunda Super Star II Tester 007-0041B before disturbing any connectors, perform the
or equivalent must be used on fast mode to properly Quick Test using Rotunda Super Star II Tester
display the On-Board Diagnostic Codes. 007-0041 B or equivalent. Refer to the
1. Required equipment: Powertrain Control/Emissions Diagnosis
1
Manual.
• Rotunda Transmission Tester 007-0085C or
equivalent.
• Rotunda Super Star II Tester 007-0041B or
equivalent. Diagnosis by Symptom Routines
• Rotunda 73 Digital Multimeter 105-00051 or The Diagnosis by Symptom Charts give the service
equivalent. . technician diagnostic information, direction and
possible components, using a SYMPTOM as a starting
• Transmission Range (TR) Sensor Cable
(Rotunda "MLPS" Manual Lever Position point. .
Sensor Cable) 007-00086, used with The Diagnosis by Symptom Charts are divided into
Transmission Tester 007-o085C or two categories: Electrical Routines, indicated by 20.0
equivalents. series numbers, and Hydraulic / Mechanical Routin~s,
indicated by 300 series numb~rs. The Electrical .
• Rotunda EEC-IV 60-Pin Breakout Box
007-00033 or equivalent. Routines list the possible electrical components that
could have caused or contribute to the symptom
2. NOTE: Some E40D transmission conditions may described. The Hydraulic / Mechanical Routines list the
cause engine concerns. An electronic pressure possible hydraulic or mechanical components that
control short circuit may cause alternate firing. could cause or contribute to the symptom described.
The torque converter clutch not disengaging will
stall the engine. . Diagnosis by Symptom Charts - Directions
Determine customer concerns relative to vehicle 1. Using the Diagnosis Routines Index, select the
usage: Symptom / Concern that best describes the
condition. . \.
• Hot or cold vehicle operating temperature 2. Turn to the Routine indicated in the Diagnosis by
• Hot or cold ambient temperatures Symptom Routine Index.
• Type of terrain 3. Always begin diagnosis of a symptom by using
• Vehicle loaded / unloaded the following:
• City / highway driving a. Preliminary Inspections
3. Fluid level and condition. b. Verification of Condition
4. Road test vehicle to verify customer concern c. Check the Fluid Level
using the shift point test and torque converter d. Perform Other Test Procedures as directed
clutch operation tests. 4. NOTE: Not all concerns and conditions with
Inspect vehicle for non-Ford approved add-on electrical components will set a Diagnostic
devices such as: Trouble Code (DTC). Be aware that the
components listed may still be the cause. Verify
- Air conditioning proper function of those components prior to
- Generators (alternators) proceeding to the Hydraulic / Mechanical Routine
- Engine turbos listed.
THEN BEGIN with the Electrical Routine if
- Cellular telephones
indicated. Follow the reference or action required
- Cruise controls statements. Always perform the On-Board
- CBradios Diagnostic Tests as required. NEVER SKIP
STEPS. Service as required. If the concern is still
- Linear boosters present after electrical diagnosis then proceed to
- Backup alarm signals the Hydraulic/Mechanical Routine listed.
- Computers


ALL RIGHTS RESERVED
5. The Hydraulic/Mechanical Routines list possible

hydraulic or mechanical components that could
cause the concern. These components are listed
in the removal sequence and by most likely
concern. You must inspect all components listed
to ensure proper repair.
Diagnosis by Symptom Index
INDEX
Routines
Mechanical
E40D Electrlcal(8) Hydraulic
Engagement Concerns
• No Forward and No Reverse None 307
• No Forward Only None 301
• No Reverse Only None 302
• Harsh Forward and Harsh Reverse 208 308
• Harsh Reverse Only 203 303
• Harsh Forward Only 204 304
• Delayed Forward and Delayed Reverse None 309
• Delayed / Soft Reverse Only None 305
• Delayed / Soft Forward Only None 306
Shift Concerns
• Timing Concerns
- Early / Late (Some / All) 211 311
- Erratic / Hunting (Some / All) 212 312
• Feel - -
- Soft / Slipping (Some / All) 213 313
- Harsh (Some / All) 214 314
• Some / All Shifts Missing 210 310
• No First Gear in Drive, Engages in a Higher Gear 215 315
• No First Gear in Manual 1st 216 316
• No Manual Second Gear 217 317
Torque Converter Operation Concerns
• Does NOT Apply 240 340
• Always Applied / Stall Vehicle 241 341
• Cycling / Shudder / Chatter 242 342
Other
• Shift Lever Efforts High None 351
• External Leaks 252 352
• Poor Vehicle Performance 253 353
• Noise / Vibration - Forward or Reverse None 354
• Engine Will Not Crank 255 355
• No Park Range None 356
• Overheating 257 357
• No Engine Braking in Manual 2 None 358
• No Engine Braking in Manual 1 259 359
• No Engine Braking with {) Cancelled 260 360
• Fluid Venting or Foaming None 361
Reference
Pressure Chart - 401
Check Ball Locations - 501
Band / Clutch Application Chart - 601
(a) Perform electrical routines first.
T0118568

ALL RIGHTS RESERVED
Diagnostic Routines
ENGAGEMENT CONCERN: NO FORWARD ONLY

Possible Component Reference / Action
201 - ELECTRICAL ROUTINE
• No Electrical Concerns
301 - HYDRAULIC/MECHANICAL ROUTINE
Fluid
• Improper level • Adjust fluid to proper level.
• Condition • Inspect per instructions under Transmission Fluid Condition Check.
Shift Linkage (Internal/External) or Cable
• Damaged, misadjusted, disconnected • Inspect and service as required. Adjust linkage as outlined. After
servicing linkage, verify that the Transmission Range (TR) sensor is
properly adjusted. Refer to Section 07-14A for Transmission Range
(TR) sensor adjustment.
Improper Pressures
• Low line pressure • Check pressure at line tap. Perform Line Pressure and Stall Tests.
Refer to Pressure Chart No. 401 for specification. if pressures are
low, check the following possible components: Pump inlet filter and
seal assembly, main controls, pump assembly, forward clutch
assembly.
Filter Assembly and Seal
• Plugged, damaged • Inspect filter assembly and seal for damage.
• Filter seal damaged, cut • Replace as required.
Main Controls
• Manual valve stuck, damaged • Inspect for damage and service as required.
• Control body housing leakage
• Bolts not tightened to specification • Retighten bolts to specification.
• Gaskets damaged • Inspect gasket for damage and replace as required.
Forward Clutch Assembly
• Assembly • Air check clutch assembly as outlined in this section.
• Stator support seal damaged • Inspection damage. Service as required.
• Piston, seal; check ball damaged, missing, not seating • Inspect seals for damage, check ball seating, location. Service
piston assembly as required.
• Feed bolt loose, missing • Install new feed bolts and tighten to specification.
• Center support damaged, holes blocked / missing • Inspect for damage. Service as .required.
• Forward clutch sealing rings damaged • Inspect for damage. Service as required.
• Forward clutch ring gear damaged • Inspect for damage. Service as required.
• Friction elements damaged, worn; spline teeth damaged, missing • Check for abnormal wear, damage. Service as required.
• Stator support seals damaged • Service as required.
Forward/Reverse Sun Gear Damaged • Inspect for damage. Service as required.
Front Planet Assembly Damaged • Inspect for damage. Service as required.
Output Shaft
• Splines damaged • Inspect for damage. Service as required.
Low One-Way Clutch Assembly (Planetary)
• Worn, damaged or misassembled • Inspect for damage. Service as required.
T0118578
ENGAGEMENT CONCERN: NO REVERSE ONLY

Fluid
• Condition • Inspect per instructions under Transmission Fluid Condition Check.
(Continued)

ALL RIGHTS RESERVED
ENGAGEMENT CONCERN: NO REVERSE ONLY (Cont'd)

P08slble Component Reference / Action
• Damaged or misadjusted • Inspect and service as required. Adjust linkage as outlined. After
properly adjusted. Refer to Section 07-14A for Transmision Range
Improper Pres8ures
• Low line pressure • Check pressure at line pressure tap. Perform Line Pressure and
Stall Tests. Refer to Hydraulic Pressure Chart No. 410 for
specifications. If pressures are low, check the following possible
components: Pump inlet filter and seal assembly, main control,
pump assembly, reverse clutch assembly, coast clutch assembly,
direct clutch assembly.
Filter A88embly and seal
• Plugged, damaged or seal missing • Inspect filter assembly and seal for damage. Service as required.
Main Control8
• Gaskets damaged • Inspect for damage and replace.
• Valve springs, main control valve body, direct clutch accumulator • Inspect for damage. Service as required.
valve damaged, stuck, missing, or misassembled
• Reinforcing plate improperly installed; bolts not torqued to • Inspect for proper installation. Retorque bolts to specification.
specification
Coa8t Clutch A88embly
• Piston seals or piston damaged • Inspect for damage. Service as required.
• Stator support seals damaged • Inspect for damage. Service as required.
Direct Clutch A88embly
NOTE: Only if 3rd gear also is inoperative
• Seals or piston damaged • Inspect for damage. Service as required.
• Clutch plates burnt, missing • Inspect for damage. Service as required.
• Check ball damaged, missing • Inspect for damage. Service as required.
• Center support damaged or holes blocked • Inspect for damage. Service as required.
• Center support hub damaged • Inspect for damage. Service as required.
Forward Planet A88embly
• Assembly damaged • Determine source of damage. Service as required.
Rever8e Clutch Assembly
• Piston bore damaged • Inspect for damage. Service as required.
• Friction elements damaged, worn; missing plates • Inspect for damage. Service as required.
• Feed hole damaged, plugged, missing • Inspect for damage. Service as required.
Reverae Planet A88embly
• Assembly damaged • Determine source of damage. Service as required.
Reverae Ring Gear
• Gears Ilugs to reverse carrier damaged • Determine source of damage. Service as required.
T0118588

ALL RIGHTS RESERVED
ENGAGEMENT CONCERN: HARSH REVERSE ONLY

Powertraln Control System
• Electrical inputs / outputs, vehicle wiring harnesses, powertrain • Run On-Board Diagnostics. Refer to Powertrain Control/Emissions
control module, throttle position sensor, vehicle speed sensor, Diagnosis Manual- for diagnosis. Perform Engagement Test,
revolutions per minute sensor, electronic pressure control Electronic Pressure Control Test and Pinpoint Test uE" using the
Transmission Tester 007-00a5C as outlined in this section. Service
as required. Clear codes, road test, rerun On-Board Diagnostics.
Improper Pressures
• High line pressure • Check pressure at line pressure tap. Perform Line Pressure and
Stall Tests. Refer to Pressure Chart No. 401 for specification. If
high, check the following possible components: main controls, filter
assembly and seal.
Main Controls
• Gasket damaged • Inspect for damage and replace.
• Electronic pressure control solenoid stuck or damaged • Perform Electronic Pressure Control Tests outlined in routine
No. 203. Service as required.
• Direct clutch accumulator valve and plunger, engagement control • Inspect for damage, contamination. Service as required.
valve, direct clutch accumulator regulator valve, springs -
stuck, misassembled, contaminated, damaged
Pump Assembly
• Main regulator / booster valve stuck, damaged, misassembled • Inspect for damage. Service as required.
Direct Clutch Assembly
• Seals damaged, missing • Inspect for direct clutch assembly for damage. Service as required.
• Stator support seals damaged
• Center support hub / seal ring damaged
• Holes blocked / missing
• Check ball damaged
• Friction elements damaged or missing
a May be purchased as a separate item.
TD11859B
ENGAGEMENT CONCERN: HARSH FORWARD ONLY

Possible Components Reference / Action
control module, throttle position sensor, engine rpm sensor, Diagnosis Manual- for diagnosis. Perform Engagement Test,
'.
vehicle speed sensor, electronic pressure control Electronic Pressure Control Test and Pinpoint Test E using the
~
Transmission Tester 007-00a5C as outlined in this section. Service
as required. Clear codes, road test, rerun On-Board Diagnostics.
304 HYDRAULIC/MECHANICAL ROUTINE
Improper Pressures
• High line pressure • Check pressure at line pressure tap. Perform Line Pressure and
Stall Tests. Refer to Pressure Chart No. 401 for specification. If
pressures are high, check main controls.
Main Controls
• Electronic pressure control solenoid stuck or damaged • Perform Electronic Pressure Control Tests outlined in routine
No. 204. Service as required.
• CB 13 check ball missing, plate seat damaged • Inspect for damage. Service as required.
(Continued)
ALL RIGHTS RESERVED
ENGAGEMENT CONCERN: HARSH FORWARD ONLY (Cont'd)

• Engagement control valve, springs - damaged, stuck, • Inspect for damage. Service as required.
misassembled, contaminated
Pump Assembly
• Direct clutch accumulator valve and plunger, engagement control • Inspect for damage, contamination. Service as required.
valve, direct clutch accumulator regulator valve, springs -
stuck, misassembled, contaminated, damaged
• Seals damaged, missing • Inspect for direct clutch assembly for damage. Service as required.
• Stator support seals damaged
• Holes blocked I missing
• Friction elements damaged or missing
• Plates burnt, missing; check ball missing, damaged; hub • Inspect for damage. Service as required.
damaged
10118608
ENGAGEMENT CONCERN: DELAYED/SOFT REVERSE ONLY

Shift Linkage or Cable
• Damaged, misadjusted • Inspect and service as required. Adjust linkage as outlined in this
section. After servicing linkage, verify that the Transmission Range
(TR) sensor is properly adjusted. Refer to Section 07-14A for
Transmission Range (TR) sensor adjustment.
Main Controls
• Direct clutch accumulator regulator valve, low reverse modulator • Inspect for damage. Service as required.
valve, springs - stuck, damaged, missing, misassembled
• Check ball missing, damaged • Inspect for damage. Service as required.
• Reinforcing plate improperly installed, bolts not tightened to • Inspect for proper installation. Retighten bolts to specification
specification
Coast Clutch Assembly • Air check clutch assembly as outlined in this section.
• Assembly • Inspect for damage. Service as required.
• Piston seals damaged, missing • Inspect for damage. Service as required.
• Seals damaged, missing • Inspect direct clutch assembly for damage. Service as required.
• Holes blocked / missing
• Friction elements damaged or missing • Inspect for damage. Service as required.
(Continued)
ALL RIGHTS RESERVED
ENGAGEMENT CONCERN: DELAYED/SOFT REVERSE ONLY (Cont'd)

Reverse Clutch Assembly
• Seals, piston damaged • Inspect for damage. Service as required.
• Friction elements - damaged, worn • Inspect for damage. Service as required.
• Assembly leakage • Inspect for damage. Service as required.
T0118618
ENGAGEMENT CONCERN: DELAYED/SOFT FORWARD ONLY

Fluid
• Condition • Inspect according to Service Manual instructions under
Transmission Fluid Condition Check.
• Damaged, misadjusted • Inspect and service as required. Adjust linkage as outlined. After
Improper Pressures
• Low line pressure • Check pressure at line tap. Perform Line Pressure and Stall Tests.
Refer to Pressure Chart No. 401 for specification. If pressures are
low, check the following possible components: pump inlet filter and
seal assembly, main controls, pump assembly.
• Plugged, damaged • Inspect filter assembly and seal for damage. Service as required.
• Filter Seal damaged
Main Controls
• Bolt not tightened to specification • Retighten bolts to specification.
Center Support Assembly
• Feedbolts missing, improperly tightened • Install new feedbolts and tighten to specification.
• Hub damaged, holes blocked or missing • Inspect for damage. Service as required.
• Seals or piston damaged • Inspect seals for damage. Service as required.
• Check balls damaged, missing • Inspect for mislocation, poor seating, damage. Replace cylinder as
required.
• Clutch hub damaged • Inspect for damage. Service as required.
• Friction elements damaged, missing • Inspect for damage. Service as required.
• Stator support seal damaged • Inspect for damage. Service as required.
T0118628
ENGAGEMENT CONCERN: NO FORWARD AND NO REVERSE ONLY

Fluid
• Improper level • Adjust fluid to proper level. Inspect according to instructions under
• Condition Transmission Fluid Condition Check.
(Continued)
ALL RIGHTS RESERVED
ENGAGEMENT CONCERN: NO FORWARD AND NO REVERSE ONLY (Cont'd)

• Damaged, misadjusted or disconnected • Inspect for damage. Service as required. Adjust linkage as
outlined. After servicing linkage, verify that the Transmission Range
Improper Pressures
• Low line pressures • Check pressure at line tap. Perform Line Pressure Test. Refer to
Pressure Chart No. 401 for specification. If pressures are low,
check the following possible components: pump inlet filter and seal
assembly, main controls, pump assembly, forward clutch assembly.
• Filter seal damaged or cut
Main Controls
• Manual valve - stuck, damaged
• Control body housing leakage • Inspect for damage. Service as required.
Pump Assembly
• Main regulator / booster valve damaged, missing, misassembled • Inspect for damage. Service as required.
• Excessive pump gear end clearance • Perform pump gear end clearance check as outlined in this section.
• Damaged, holes blocked. • Inspect for damage. Service as required.
• Feedbolts missing or improperly tightened • Install new bolts and tighten to specification.
Forward/Rever8e Sun Gear
• Damaged • Inspect for damage. Service as required.
Forward Planet A88embly
Input Shaft/Center Shaft/Output Shaft
• Splines damaged • Inspect for damage. Service as required.
Overdrive Carrier
Drive In €) with €>Cancelled
Note: For Dlagn08tlc purpose8 only. Not for extended driving.
Overdrive OWC
• Misassembled, damaged • Inspect for damage. Service as required.
• Sprags or races damaged • Inspect for damage. Service as required.
10118638
ENGAGEMENT CONCERN: HARSH FORWARD AND REVERSE

P08slble Component8 Reference / Action
Powertreln Control System
• Electrical inputs / outputs, vehicle wiring harnesses, powertrain • Run On-Board Diagnostics. Refer to PC / ED Manual· for diagnosis.
control module, electronic pressure control, throttle position Perform Engagement Test, EPC Test and Pinpoint Test liE" using
sensor the Transmission Tester 007-00a5C. Service as required. Clear
codes, road test and rerun On-Board Diagnostics.
Improper Pres8ure8
• High line pressure • Check pressure at line pressure taps. Perform Line Pressure Test.
Refer to Pressure Chart No. 401 for specification. If high, check
main controls.
(Continued)
ALL RIGHTS RESERVED
ENGAGEMENT CONCERN: HARSH FORWARD AND REVERSE (Cont'd)

Main Controls
• Gasket damaged • Inspect for damage and replace.
• Electronic pressure control solenoid stuck or damaged • Perform Electronic Pressure Control Tests in routine No. 208.
• Engagement control valve stuck, damaged, contaminated, • Inspect for damage, contamination. Service as required.
misassembled
Pump Assembly
T0118648
ENGAGEMENT CONCERN: DELAYED/SOFT FORWARD AND REVERSE

Fluid
• Improper level • Adjust to proper level.
Improper Pressures
• Low line pressure • Check pressure at line tap. Refer to Pressure Chart No.. 401 for
specification. If low check the following components: pump inlet
filter / seal assembly, main control, pump assembly.
• Seal damaged, cut
Main Controls
• Springs - stuck, damaged, missing, misassembled • Inspect for damage. Service as required.
Torque Converter Dralnback Initial Engagement Only • Refer to Converter drainback test procedures in this section for
diagnosis.
T0118658
SHIFT CONCERNS: SOME OR ALL SHIFTS MISSING

Powertraln Control System • Perform Shift Point Test.
• Electrical inputs / outputs, vehicle wiring harness, powertrain • Run On-Board Diagnostics. Refer to Powertrain Control/Emissions
control module, throttle position sensor, engine rpm sensor, Diagnosis Manual- for diagnosis. Perform Service Manual Pinpoint
Transmission Range (TR) sensor, vehicle speed sensor, shift Tests UA" and leD" using the Transmission Tester 007-0085C and
solenoid 1, shift solenoid 2 the Transmission Range (TR) Sensor Cable (UMLPS" Manual Lever
Position Sensor Cable) 007-00086 as outlined in this section.
Service as required. Clear code, road test, rerun On-Board
Diagnostics.
(Continued)

ALL RIGHTS RESERVED
SHIFT CONCERNS: SOME OR ALL SHIFTS MISSING (Cont'd)

Fluid
• Improper level • Adjust fluid to proper level. Inspect according to instructions under
• Condition Transmission Fluid Condition Check.
• Damaged, misadjusted, disconnected • Inspect and service as required. Adjust linkage as outlined. After
• Filter seal damaged
Main Controls
• Valves stuck, damaged, misassembled • Inspect for damage. Service as required.
For diagnosis related to a specific shift see Reference / Action. • To diagnose specific No Shift refer to the appropriate shift routine.
No Shift 1-2, Routine 220/320
No Shift 2-3, Routine 221 /321
T0118668
SHIFT CONCERNS: SHIFT TIMING - EARLY /LATE

Powertraln Control System • Perform Shift Point Test.
control module, throttle position sensor, transmission fluid Diagnosis Manual· for diagnosis. Perform Service Manual Pinpoint
temperature sensor, vehicle speed sensor, shift solenoid 1, shift Tests IIA", and liB" using the Transmission Tester007-0085C as
solenoid 2, engine rpm outlined in this section. Service as required. Clear codes, road test
and rerun On-Board Diagnostics.
Other Electrical Concerns
• No power to powertrain control module, Keep Alive Memory • Restore memory by performing Drive Cycle Test.
erased from powertrain control module
• Programmable Speedometer / Odometer Module improperly • Refer to this section for programmable speedometer / odometer
programmed or damaged module diagnostic and programming procedures.
Other
• Tire size change • Refer to the specification decal on door panel and verify that
vehicle has original equipment. Changes in tire size or axle ratio
may affect shift timing.
• Speedometer gear change (model dependant)
• Axle ratio change
Power/Engine Performance - Poor Engine Performance • Refer to Routine No. 253/353.
Main Controls
• Valves, accumulators, stuck or damaged • Inspect for damage, contamination. Service as required.
For diagnosis related to a specific shift or if all above are OK see • To diagnose specific shift / timing concern refer to Soft / Slipping
Reference / Action. routines:
(Continued)

ALL RIGHTS RESERVED
07·01A·39 Transmission, Automatic, E40D 07·01A-39
SHIFT CONCERNS: SHIFT TIMING - EARLY /LATE (Cont'd)

Soft/Slipping Shift 1-2, Routine 226/326
Downshifts, 229/329
T0118678
SHIFT CONCERNS: TIMING - ERRATIC/HUNTING

Powertraln Control System • Perform Shift Point and Torque Converter Clutch Tests.
• Vehicle wiring harnesses, powertrain control module, electrical • Run On-Board Diagnostics. Refer to PC / ED Manual- for diagnosis.
inputs / outputs, throttle position sensor, engine rpm sensor, Perform Service Manual Pinpoint Tests IIA", uB", "C", liD" using
transmission fluid temperature sensor, shift solenoid 1, shift the Transmission Tester 007-0085C and the Tranmsission Range
solenoid 2, manual lever position sensor, torque converter (TR) Sensor Cable (IIMLPS" Manual Lever Position Sensor Cable)
solenoid 007-00086 as outlined in this section. Service as required. Clear
With Speed Control "ON"
• Torque converter cycling • Re-evaluate with Speed Control 1I0FF" or depress Transmission
• Shift cycling (3-4 / 4-3 shifts) Control Switch (overdrive cancelled). If condition still exists
proceed with diagnosis.
Fluid
• Filter seal damaged
Main Control
• Valves, accumulators, damaged, stuck • Inspect for damage. Service as required.
• Wrong parts used in rebuild • Verify that proper parts were used.
Torque Converter Clutch • Refer to torque converter cycling (No. 342).
• Refer to the following shift routine(s) for further diagnosis:
For further diagnosis for timing issues refer to Reference / Action.
Shlfta No Soft/Slip Hersh
1-2 220/320 226/326 232/332
2-3 2211321 227/327 233/333
3-4 222/322 2281328 234/334
4-3 223fJ23 2291329 235f335
3-2 224/324 229/329 236/336
2-1 225/325 2231329 2371337
CD11321-A

T0118688
1995 F-150, F-250, F-350, Bronco, ~-Super Duty Powertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
SHIFT CONCERNS: FEEL - SOFT/SLIPPING

Powertraln Control System • Perform Shift Point Tests.
a
• Electrical inputs / outputs, vehicle wiring harnesses, powertrain • Run On-Board Diagnostics. Refer to PC / ED Manual for diagnosis.
control module, throttle position sensor, engine rpm sensor, Perform Service Manual Pinpoint Tests UE" and UB" using the
electronic pressure control, transmission fluid temperature Transmission Tester007-0085C as outlined in this section. Service
sensor as required. Clear codes, road test, rerun On-Board Diagnostics.
Fluid
• Condition • Inspect according to instructions in this section under Transmission
Fluid Condition Check.
Improper Pressures
• Low line pressure • Check pressures at line pressure tap. Perform Line Pressure Tests.
Refer to Pressure Chart No. 401 for specifications. If pressures are
low or all shifts are soft / slipping, go to main control.
Main Controls
• Line modulator valve springs damaged, stuck, misassembled • Inspect for damage, contamination. Service as required.
• Electronic pressure control solenoid malfunction • Refer to Electrical Routine No. 213.
• Accumulator assembly damaged or wrong assembly • Inspect for damage. Service as required. Verify correct assembly is
used.
Pump Assembly
• Main regulator / booster valve damaged, misassembled • Inspect for damage. Service as required.
• Electronic pressure control air bleed check valve damaged or • Inspect for damage. Service as required.
missing
• Refer to the following Shift Routine(s) for further diagnosis:
For diagnostics related to specific shifts see Reference / Action. Soft/Slipping Shift 1-2, Routine 226/326
Downshifts, 229/329
T0118698
SHIFT CONCERNS: FEEL - HARSH

• Electrical inputs / outputs, vehicle wiring harnesses, powertrain • Run On-Board Diagnostics. Refer to PC / ED Manual a for diagnosis.
control module, electronic pressure control, transmission fluid Perform Service Manual Pinpoint Tests uB", --0" and UE" using the
temperature sensor, throttle position sensor, engine RPM sensor, Transmission Tester 007-0085C and the Transmission Range (TR)
manual lever position switch Sensor Cable (UMLPS" Manual Lever Position Sensor Cable)
007-00086 as outlined in this section. Service as required. Clear
a
Engine Performance Issues • Refer to PC / ED Manual for diagnosis.
Fluid
• Condition • Inspect according to instructions in this section under Transmission
Fluid Condition Check.
Improper Pressures
• High line pressure • Check pressures at line pressure tap. Perform Line Pressure and
Stall Tests. Refer to Pressure Chart No. 401 for specifications. If
pressures are high or all shifts are harsh, go to main control.
(Continued)

ALL RIGHTS RESERVED
SHIFT CONCERNS: FEEL - HARSH (Cont'd)

Main Controls
• Line modulator valve / spring misassembled. stuck. damaged • Inspect for damage. contamination.
• Electronic pressure control solenoid malfunction • Service as required.
• Accumulator assembly damaged or wrong assembly • Refer to Electrical Routine No. 214.
• Inspect for damage. Service as required. Verify correct assembly is
used.
Pump Assembly
• Main regulator / booster valve damaged. misassembled • Inspect for damage. Service as required.
Refer to the following Shift Routine(s) for further diagnosis:
For diagnostics related to a specific shift see Reference / Action. Harsh Shift 1-2. Routine 232/332
Harsh Shift 2-3. Routine 233/333
Harsh Shift 2-1. Routine 237 /337
TD11870B
SHIFT CONCERNS: NO 1ST GEAR, ENGAGES IN HIGHER GEAR

Possible Component Reference/Action
• Electrical inputs / outputs, vehicle wiring harnesses. powertrain • Run On-Board Diagnostics. Refer to Powertrain Control/Emissions
control module, shift solenoid 1, shift solenoid 2, manual lever Diagnosis Manual- for diagnosis. Perform Service Manual Pinpoint
position sensor Tests A" and 110" using the Transmission Tester 007-0085C and
II
the Transmission Range (TR) Sensor Cable (IIMLPS" Manual Lever

Position Sensor Cable) 007-00086 as outlined in this manual.
Service as required. Clear codes. road test and rerun On-Board
Diagnostics.
Shift Linkage (Internal/External) or Cables, Transmission
Range (TR) Sensor
• Damaged. not connected, misadjusted • Inspect and service as required. Adjust linkage as outlined. After
servicing linkage. verify that the Transmission Range (TR) sensor is
Main Controls
• Gaskets damaged. misaligned • Inspect for damage and replace.
• Shift solenoid 1. shift solenoid 2 stuck or damaged • Refer to Electrical Routine No. 215.
• Solenoid regulator valve. 2-3 shift valve, 3-4 shift valve. 02 valve • Inspect for damage. Service as required.
- stuck. missing. misassembled. damaged
• Air bleeds for S 1-S2 circuits missing • Inspect for damage. Replace case.
• Wrong components used in rebuild • Verify that proper components were used. Service as required.
Mechanical
• Band servo. clutches damaged • Refer to proper disassembly procedures in this section.
For diagnosis related to a specific gear, use Transmission Tester to Refer to the following routine(s) for further diagnosis
determine gear. Shift 1-2. Routine 220/320
Shift 2-3, Routine 221 /321
Shift 3-4. Routine 222/322
(Continued)
1995 F-150. F-250, F-350. Bronco. F-Super Duty Powertrain. Drivetrain July 1994

ALL RIGHTS RESERVED
SHIFT CONCERNS: NO 1ST GEAR, ENGAGES IN HIGHER GEAR (Cont'd)

Reverse Ring Gear
• Damaged gear lugs to reverse carrier • Inspect for damage. Service as required.
Low One-Way Clutch
• Damaged, misassembled • Inspect for damage, proper assembly. Service as required.
10118718
SHIFT CONCERNS: NO MANUAL 1ST GEAR

control module, shift solenoid 1, shift solenoid 2, Transmission Diagnosis Manual· for diagnosis. Perform Service Manual Pinpoint
Range (TR) sensor Tests IIA" and liD" using the Transmission Tester 007-0085C and
the Transmission Range (TR) Sensor Cable (IIMLPS" Manual Lever
Service as required. Clear codes, road test and rerun On-Board
Diagnostics.
• Damaged, misadjusted, not connected • Inspect for damage. Service as required. Adjust linkage as
Main Controls
• Manual control lever, manual valve, low reverse modulator valve, • Inspect for damage. Service as required.
1-2 shift valve, 2-3 shift valve, BS 1 check ball, 4-3-2 timing valve
- stuck, damaged
• Shift solenoid 1 malfunction • Refer to Electrical Routine No. 216.
• Air bleed for shift solenoid 1 circuit damaged or missing • Inspect for damage. Replace case.
Low One-Way Clutch Assembly
• Damaged, misassembled • Inspect for damage. Service as required.
10118728
SHIFT CONCERNS: NO MANUAL 2ND GEAR

control module, shift solenoid 1, shift solenoid 2, Transmission Diagnosis Manual· for diagnosis. Perform Service Manual Pinpoint
Range (TR) sensor Tests II A" and liD" using the Transmission Tester 007-0085C and
the Transmission Range (TR) Sensor Cable ("MLPS" Manual Lever
Service as required. Clear codes, road test and rerun On-Board
Diagnostics.
• Damaged, misadjusted • Inspect for damage. Service as required. Adjust linkage / cable as
outlined. After servicing linkage / cable, verify that the Transmission
Range (TR) sensor is properly adjusted. Refer to Section 07-14A
for Transmission Range (TR) sensor adjustment.
(Continued)

ALL RIGHTS RESERVED
SHIFT CONCERNS: NO MANUAL 2ND GEAR (Cont'd)

Main Controls
• 2-3 shift valve, 3-4 shift valve, manual 1-2 transition valve, spring • Inspect for damage. Service as required.
- stuck, damaged, missing, misassembled
• BS2, BS6, BS 1 - missing, leaks or seats damaged • Inspect for damage. Service as required.
• Improper parts used in rebuild • Verify that proper parts were used.
Intermediate Clutch Assembly
• Friction elements worn, missing, damaged, misassembled • Inspect for damage. Service as required.
• Ball check stuck / missing • Inspect for damage. Service as required.
• Feedbolt torque incorrect, leaks, missing • Inspect and retighten bolts as required.
• Cylinder assembly outer diameter / case bore damaged, leaking • Inspect for damage. Service as required.
Intermediate One-Way Clutch Assembly
• Case / sprags damaged, improperly assembled on inner race • Inspect for damage. Service as required.
T0118738
SHIFT CONCERNS: NO 1-2 SHIFT (AUTOMATIC)

control module, throttle position sensor, vehicle speed sensor, Diagnosis Manual- for diagnosis. Perform Service Manual Pinpoint
shift solenoid 1, shift solenoid 2 Test A" using the Transmission Tester 007-00a5C as outlined in
Ie
this section. Service as required. Clear codes, road test and rerun
On-Board Diagnostics.
• Damage, misadjusted • Inspect for damage. Service as required. Adjust linkage as
• Transmission Range (TR) sensor damaged, misadjusted outlined. After servicing linkage, verify that the Transmission Range
Main Controls
• Gaskets damaged, misaligned • Inspect for damage and replace.
• 02 valve, 1-2 shift valve, 1-2 manual transition valve, • Inspect for damage. Service as required.
intermediate clutch accumulator regulator valves, springs -
stuck, damaged, missing or misassembled
• Air bleed for shift solenoid 2 circuit damaged or missing • Inspect for damage. Replace case.
• Friction elements worn, missing, damaged, misassembled • Inspect for damage. Service as required.
• Ball check stuck / missing • Inspect for damage. Service as required.
• Feedbolt torque incorrect, leaks, missing • Inspect and retighten bolts as required.
• Cylinder assembly outer diameter / case bore damaged, leaking • Inspect for damage. Service as required.
Intermediate One-Way Clutch Assembly
• Cage / sprags damaged, improperly assembled on inner race • Inspect for damage. Service as required.
• Improper components used in rebuild • Verify that proper components are used.
T0118748

ALL RIGHTS RESERVED

P0881ble Component Reference / Action
Powertraln Control SY8tem
• Electrical inputs / outputs, vehicle wiring harness, powertrain • Run On-Board Diagnostics. Refer to Powertrain Control/Emissions
control module, throttle position sensor, vehicle speed sensor, Diagnosis Manual· for diagnosis. Perform Service Manual Pinpoint
II
Main Control8
• SS 1 malfunction • Refer to Electrical Routine No. 221.
• Direct clutch accumulator regulator valve, 2-3 shift valve, springs • Inspect for damage. Service as required.
- stuck, missing, damaged, misassembled
• Air bleed for SS2 circuit damaged or missing • Inspect for damage. Replace case.
• Improper components used in rebuild • Verify that proper components are used.
Center Support A88embly
• Feedbolts missing, not tightened to specification • Inspect, install new feedbolts and tighten to specification.
• Seal rings damaged • Inspect for damage. Service as required.
• Assembly damaged • Inspect for damage. Service as required.
• Outside diameter or case bore damaged or leaking • Inspect for damage. Service as required.
Direct Clutch A88embly
• Seals, piston, cylinder damaged • Inspect for damage. Service as required.
• Friction elements missing or damaged • Inspect for damage. Service as required.
• Ball check missing, damaged • Inspect for damage. Service as required.
T0118758

P0881ble Component Reference / Action
Powertraln Control SY8tem
• Electrical inputs / outputs, vehicle wiring harnesses, powertrain • Run On-Board Diagnostics. Refer to Powertrain Control/Emission
II
Main Control8
• Gaskets damaged or misaligned • Inspect for damage and replace.
• Shift solenoid 1, shift solenoid 2 malfunction • Refer to Electrical Routine No. 222.
• Overdrive accumulator regulator valve and spring, 3-4 shift valve • Inspect for damage. Service as required.
and spring - damaged, stuck, misassembled, missing
• Improper components used in rebuild • Verify that proper components were used in the rebuild.
Overdrive Clutch A88embly
• Clutch plates burnt, missing • Inspect for damage. Service as required.
• Cylinder damaged • Inspect for damage. Service as required.
• Feedbolts loose, missing, leaking, seals damaged • Install new feedbolts and tighten to specifications.
• Cylinder check ball missing • Inspect for damage. Service as required.
(Continued)

ALL RIGHTS RESERVED
SHIFT CONCERNS: NO 3-4 SHIFT (AUTOMATIC) (Cont'd)

Overdrive One-Way Clutch Assembly
Overdrive Planet Assembly
T0118768.

Possible Component Reference/ Action
shift solenoid 2 Test" A" using the Transmission Tester 007-00a5C as outlined in
Main Controls
• BS2, 3-4 shift valve damaged, missing, misassembled, stuck • Inspect for damage. Service as required.
T0118778

shift solenoid 1 Tests" A" and "0" using the Transmission Tester 007-00a5C as
outlined in this section. Service as required. Clear codes, road test
and rerun On-Board Diagnostics.
Main Controls
• 3-2 shift valve, stuck, damaged • Inspect for damage. Service as required.
T0118788

Powertraln C.ontrol System
• Electrical inputs / outputs, vehicle wiring harnesses, powertrain • Run On-Board Diagnostics. Refer to Powertrain Con"trol / Emissions
shift solenoid 2 Test" A" using the Transmission Tester 007-00a5C as outlined in
., this section. Service as required. Clear codes, road test an~ rerun
(Continued)

ALL RIGHTS RESERVED
SHIFT CONCERNS: NO 2-1 SHIFT (AUTOMATIC) (Cont'd)

Main Controls
• Gaskets, separator plate damaged, misaligned • Inspect for damage and replace.
• 02 shift valve damaged, stuck • Inspect for damage. Service as required.
TD11879B
SHIFT CONCERNS: SOFT/SLIPPING 1-2 ONLY (AUTOMATIC)

control module Diagnosis Manual e for diagnosis. Service as required.
Main Controls
• Intermediate clutch accumulator regulator valve or plunger, • Inspect for damage. Service as required.
springs - stuck, damaged, missing or misassembled
• Wrong parts used in rebuild • Verify that correct parts were used.
• Friction elements worn, missing, misassembled or damaged • Inspect for damage. Service as required.
• Feedbolt torque incorrect, missing • Inspect and install new feedbolts and tighten to specification.
• Ball check missing, not seating • Inspect for damage. Service as required.
• Cylinder assembly outer diameter / case bore damaged • Inspect for damage. Service as required.
TD11880B

control module Diagnosis Manual e for diagnosis. Service as required.
Main Controls
, • Bolts not tightened to specification • Retighten bolts to specification.
• Direct clutch accumulator regulator valve, plungers, springs - • Inspect for damage. Service as required.
stuck, missing, damaged, misassembled
• Improper parts used in rebuild • Verify that correct parts were used.
• Feedbolts missing, not tightened to specification • Inspect, install new feedbolts and tighten to specification.
• Assembly damaged • Inspect for damage. Service as required.
(Continued)

ALL RIGHTS RESERVED
SHIFT CONCERNS: SOFT/SLIPPING 2-3 ONLY (AUTOMATIC) (Cont'd)

• Seals, piston, cylinder damaged • Inspect for damage. Service as required.
• Friction elements burnt, missing • Inspect for damage. Service as required.
• Improper quantity of plates installed • Inspect for proper quantity. Service as required.
• Intermediate brake drum inner diameter damaged • Inspect for damage. Service as required.
T0118818

control module Diagnosis Manual- for diagnosis. Service as required.
Main Controls
• Overdrive accumulator regulator valve and spring, overdrive • Inspect for damage. Service as required.
accumulator plunger and springs, damaged, misassembled,
stuck, missing
Overdrive Clutch Assembly
• Cylinder damaged, seals damaged • Inspect for damage. Service as required.
• Feedbolts loose, missing, leaking, not tightened to specification • Install new feed bolts and tighten to specification.
• Cylinder check ball not seating, missing • Inspect for damage. Service as required.
T0118828
SHIFT CONCERNS: SOFT/SLIPPING DOWNSHIFTS (AUTOMATIC)

Main Controls
• CB7 check ball missing, wrong • Inspect for damage. Service as required.
• Valve body separating plate damaged • Inspect for damage. Service as required.
T0118838

ALL RIGHTS RESERVED
SHIFT CONCERNS: HARSH 1·2 SHIFT ONLY (AUTOMATIC)

control module Diagnosis Manual· for diagnosis. Service as required.
Main Controls
• Intermediate clutch accumulator regulator valve or plunger • Inspect for damage. Service as required.
springs - stuck, damaged, missing or misassembled
• Friction elements missing or misassembled, damaged or • Inspect for damage. Service as required.
improper quantity of plates installed
• Ball check missing • Inspect for damage. Service as required.
TOl18848

Main Controls
• Direct clutch accumulator regulator valve, plungers, springs • Inspect for damage. Service as required.
stuck, missing, damaged, misassembled
• Seals, piston or cylinder damaged • Inspect for damage. Service as required.
• Friction elements damaged, missing or improper quantity of • Inspect for damage. Service as required.
plates were installed
• Intermediate brake drum inner diameter damaged or worn • Inspect for damage. Service as required.
T0118858

(Continued)

ALL RIGHTS RESERVED
SHIFT CONCERNS: HARSH 3-4 SHIFT ONLY (AUTOMATIC) (Cont'd)

Main Controls
• Overdrive accumulator regulator valve and spring, overdrive • Inspect for damage. Service as required.
accumulator plunger and springs, stuck, damaged,
misassembled, missing
• Improper parts used in rebuild • Verify that proper parts were used.
Overdrive Clutch Assembly
• Cylinder damaged, seals damaged, retaining ring not seated • Inspect for damage. Service as required.
• Feedbolts loose, missing, leaking • Install new feedbolts and tighten to specification.
• Cylinder check ball missing or not seating • Inspect for damage. Service as required.
T0118868
SHIFT CONCERNS: HARSH 4-3 SHIFT ONLY (AUTOMATIC)

Main Controls
• CB7 check ball missing • Inspect for damage. Service as required.
• Separator plate damaged • Inspect for damage. Service as required.
T0118878

Main Controls
• CB6 check ball missing • Inspect for damage. Service as required.
T0118888
ALL RIGHTS RESERVED

Main Controls
• CB 14 check ball missing • Inspect for damage. Service as required.
T0118898
TORQUE CONVERTER CLUTCH OPERATION CONCERN: NO APPLY

Powertraln Control System • Perform Torque Converter Clutch Operation Test.
control module, torque converter control solenoid, brake on / off Diagnosis Manual- for diagnosis. Perform Torque Converter
switch, throttle position sensor, engine rpm sensor, transmission Engagement Test and Pinpoint Tests liB" and IIC" using the
fluid temperature sensor Transmission Tester 007-00a5C as outlined in this section. Service
as required. Clear codes, road test and rerun On-Board
Diagnostics.
Main Controls
• Torque converter clutch solenoid or transmission fluid • Refer to Electrical Routine No. 240.
temperature sensor malfunction
• Gaskets damaged • Inspect gasket for damage and replace.
Pump Assembly
• Cross leaks, cup plugs missing • Inspect for porosity / leaks, cup plugs missing, replace pump as
required.
• Gaskets damaged • Inspect and replace gaskets.
• Converter clutch control valve and regulator valve stuck", • Inspect for damage. Replace pump.
misassembled, damaged
Stator Support
• Teflon~ seals damaged, leaking • Inspect for damage. Service as required.
Torque Converter Assembly
• Leakage, friction material damaged, internal seals damaged • Inspect according to procedures outlined. Service as required.
a May be purchased as a separate item. "
T0118908
TORQUE CONVERTER CLUTCH OPERATION CONCERN: ALWAYS APPLIED/STALLS VEHICLE

(SEE NOTE IN NO. 241 BEFORE PROCEEDING)
NOTE: Stalls in Drive and Manual 2 ONLY (Manual 1 and Reverse • Go to Hydraulic Mechanical No. 341.
are OK) • Perform Torque Converter Clutch Operation Test.
• Electrical inputs / outputs, vehicle wiring harnesses, powertrain • Run On-Board Diagnostics. Refer to Powertrain Control/Emission
control module, torque converter control solenoid Diagnosis Manual- for diagnosis. Perform Torque Converter
Engagement Test and Pinpoint Test IIC" using the Transmission
Tester 007-00a5C as outlined in this section. Service as required.
Clear codes, road test and rerun On-Board Diagnostics.
(Continued)
ALL RIGHTS RESERVED
TORQUE CONVERTER CLUTCH OPERATION CONCERN: ALWAYS APPLIED/STALLS VEHICLE

(SEE NOTE IN NO. 241 BEFORE PROCEEDING) (Cont'd)
Improper Pressures
• Low line pressures • Check line pressure at line tap. Perform Line Pressure and Stall
Tests. Refer to Pressure Chart No. 401 for specification.
Main Controls
• Torque converter clutch solenoid malfunction • Refer to Electrical Routine No. 341.
Pump Assembly
• Converter clutch control valve misassembled, stuck, damaged • Inspect for damage. Service as required.
• Porosity / cross leaks • Inspect for porosity / leaks, valve damaged, replace pump as
required.
• Excessive pump gear end clearance • Perform pump gear end clearance check as outlined in this section.
• End clearance (NONE) • Perform end clearance check as outlined in this section.
• Piston plate damaged / stuck to cover • Inspect for damage. Service as required.
• Inspect transmission cooling system for proper lube flow. Follow
the procedures in this section.
10118918
TORQUE CONVERTER CLUTCH OPERATION CONCERN: CYCLING/SHUDDER/CHATTER

• Electrical inputs / outputs, vehicle harnesses, powertrain control • Refer to Powertrain Control/Emissions Diagnosis Manual· for
module, torque converter solenoid, transmission range (TR) diagnosis. Perform Torque Converter Engagement Test and
sensor, brake on / off switch, throttle position sensor, engine RPM Pinpoint Tests uC" and uD" using the Transmission Tester
sensor 007-0085C or Transmission Range (TR) Sensor Cable uMLPS"
Manual Lever Position Sensor Cable 007-00086 as outlined in this
section. Clear codes, road test and rerun On-Board Diagnostics.
Speed Control Equipped Vehicles NOTE: Refer to Routine No. 212 before you proceed to No. 342.
Fluid Condition
• Inspect fluid condition. If burnt or contaminated drain fluid from the
transmission assembly and converter assembly. Check control
attaching bolts for proper torque. Retighten as required. Record
and erase On-Board Diagnostics codes. Bring vehicle to normal
operating temperature. Perform Drive Cycle as outlined in this
section. Perform On-Board Diagnostics. If condition still exists,
continue diagnosis.
Main Controls
• Torque converter clutch solenoid malfunction • Refer to Electrical Routine No. 242.
Pump Assembly
• Cross leaks • Inspect for porosity / leaks, valve damage; replace pump as
required.
• Converter clutch regulator valve damaged • Inspect for damage. Se~ice as required.
(Continued)
ALL RIGHTS RESERVED
TORQUE CONVERTER CLUTCH OPERATION CONCERN: CYCLING/SHUDDER/CHATTER (Cont'd)

Stator Support
• TeflonlP) seal on nose of stator damaged, cut, leaking • Inspect for damage. Service as required.
• End clearance (excessive), internal leakage • Inspect according to previous outline. Service as required.
10118928
OTHER CONCERNS: SHIFT LEVER EFFORTS HIGH

Manual Control Lever
• Retaining pin damaged, nut loose (inner or outer), detent spring • Inspect for damage. Service as required. Inspect locking nuts for
- bent / damaged, park mechanism damaged proper torque, retighten to proper specification as required.
Main Controls
• Manual valve sticking • Inspect for damage. Service as required.
10118938
OTHER CONCERNS: EXTERNAL LEAKS

Engine Rear Seal • Locate source and service as required.
Seals/Gaskets
• Torque converter assembly, pump, transmission oil pan, • Locate source and service as required.
transmission connector, extension housing - gasket seal,
manual lever, oil level indicator, oil filler tube, pump bolts
Other
• Cooler fitting, pressure taps, converter drain plug, band anchor • Locate source and service as required.
pins, cooler tubes, case porosity, case cracked
• Vent blocked or damaged • Check vent for damage or blockage. Service as required.
• Overfilled transmission • Check level and adjust as required.
• Overheating • Refer to routines No. 257 / 357.
• Pump assembly • Locate source and service as required.
10118948
ALL RIGHTS RESERVED
OTHER CONCERNS: POOR VEHICLE PERFORMANCE

P0881ble Component Reference I Action
Powertraln Control SY8tem • Perform torque converter clutch operation tests.
control module, other engine related items, torque converter Diagnosis Manual- for diagnosis. Perform Service Manual Pinpoint
clutch solenoid, throttle position sensor, Transmission Range Tests uB", uC" and uD" using the Transmission Tester 007-0085C
(TR) sensor, transmission fluid temperature sensor and the Transmission Range (TR) Sensor Cable uMLPS" Manual
Lever Position Sensor Tester Cable 007-00086 as outlined in this
section. Service as required. Clear codes, road test and rerun
Shift Linkage (Internal I External) or Cable
• Damaged, misadjusted • Inspect for damage. Service as required. Adjust linkage as
Shift Scheduling • Perform Shift Point Test procedure as outlined in this section.
• Improper • Go to the appropriate diagnostic routines for shift concerns
No.210-211.
Engagement8
• Improper gear selection • Go to the appropriate diagnostic routines for shift concerns
No.215/315.
Converter Clutch AlwaY8 Applied • Go to routine No. 341.
Converter One-Way Clutch
• Damaged • Go to Torque Converter Diagnosis in this section.
T0118958
OTHER CONCERNS: NOISE/VIBRATION - FORWARD OR REVERSE

P0881ble Component Reference I Action
For Nol8e8/Vlbratlon8 that change with engine 8peed:
• Torque converter components • Locate source of disturbance. Service as required.
• Fluid level (low) pump cavitation
• Pump assembly
• Engine drive accessories
• Transmission oil cooler lines grounding out
• Flywheel
• Oil filler tube grounding out
For Nol8e/VIbratlon8 that change with vehicle 8peed:
• Engine mounts • Locate source of disturbance. Service as required.
• Loose, damaged • For specific shifts or torque converter concern, refer to appropriate
• Driveline concerns routines:
• U-joints • No Shift 1-2, Routine 320
• Rear axle assembly • No Shift 2-3, Routine 321
• Suspension • No Shift 3-4, Routine 322
• Modifications / misalignment • No Shift 4-3, Routine 323
• No Shift 3-2, Routine 324
• No Shift 2-1, Routine 325
• No Converter Cycling, Routine 242/342
(Continued)

ALL RIGHTS RESERVED
07-01 A-54 Transmission, Automatic, E40D 07-01A-54
OTHER CONCERNS: NOISE/VIBRATION - FORWARD OR REVERSE (Cont'd)

• 1st gear
• One-way clutch, gear set
• Friction elements
• Torque converter assembly
• 2nd gear
• Intermediate OWC
• 3rd gear
• One-way clutch
• 4th gear
• One-way clutch
• Gear set
• Reverse
• Gear set
• Shaft spline fit
• Slip yoke, park gear
Other Noises/Vibrations:
• Main controls • Locate source of disturbance. Service as required.
• Valve resonance
• Shift cable
• Vibration, grounding
• Transmission oil cooler lines or oil filler tube
• Grounding
T0118968
OTHER CONCERNS: ENGINE WILL NOT CRANK

control module, Transmission Range (TR) sensor Diagnosis Manual- for diagnosis. Perform Service Manual Pinpoint
Test liD" using Transmission Tester007-0085C and Transmission
Range (TR) Sensor Cable (IIMLPS" Manual Lever Position Sensor
Tester Cable 007-00086) as outlined in this section. Service as
required. Clear codes, and rerun On-Board Diagnostics.
Shift Linkage (Internal/External) or Cable/Manual Lever
Position Sensor
properly adjusted. Refer to Section 07-14A for the Transmission
Range (TR) sensor adjustment procedure.
Pump Assembly
• Seized • Refer to the oil pump Disassembly and Assembly procedures in this
section. Inspect for damage. Service or replace as required.
Flywheel
T0118978

ALL RIGHTS RESERVED
07-01A-55 Transmission, Automatic, E40D 07-01 A-55
OTHER CONCERNS: NO PARK RANGE

• Damaged, misadjusted • Inspect for damage. Service as required. Adjust linkage as
(TR) sensor is properly adjusted. Refer to Section 07-14A for the
Transmission Range (TR) sensor adjustment procedure.
Park Mechanism
• Park gear, parking pawl, parking pawl return spring, park guide • Inspect for damage. Service as required.
plate, parking pawl shaft, parking pawl actuating rod, manual
control lever, damaged, misassembled
10118988
OTHER CONCERNS: TRANSMISSION OVERHEATING

control module, torque converter clutch solenoid Diagnosis Manual- for diagnosis. Perform Service Manual Pinpoint
Test caC" using the Transmission Tester 007-00a5C as outlined in
Excessive Vehicle or Towing Loads, Severe Vehicle Usage • Refer to the Vehicle Specification Manual for load and GVW / GCW
information. Refer ~o Owner's Manual.
• NOTE: If auxiliary cooler is desired use ONLY Ford Original Factory
Equipment installed to factory specifications.
Fluid
• Improper level • Adjust fluid to proper level. Inspect according to Service Manual
• Condition instructions under Transmission Fluid Condition Check.
Transmission Cooling System
• Damaged, blocked, restricted, or improperly installed • Perform Transmission Fluid Cooler Flow Test.
• Inspect for damage, restrictions. Service as required.
Vehicle Concerns Causing Engine Overheating • Refer to Engine Condition and Cause charts.
Torque Converter Clutch
• Not engaging • See Routine No. 240/340.
10118998
OTHER CONCERNS: NO ENGINE BRAKING IN MANUAL 2 POSITION ONLY

Main Controls
• BS 1, BS6, BS2, CB 1 check balls missing, seat damaged • Inspect for damage. Service as required.
• 4-3-2 timing valve, 02 valve, 2-3 shift valve, coast clutch shift • Inspect for damage. Service as required.
valve, 1-2 manual transition valve, 3-4 shift valve damaged,
stuck, misassembled
(Continued)
ALL RIGHTS RESERVED
07-01A-56 Transmission, Automatic, E40D 07-01 A-56
OTHER CONCERNS: NO ENGINE BRAKING IN MANUAL 2 POSITION ONLY (Cont'd)

Coast Clutch Assembly
• Stator support damaged or holes blocked, seal rings d.amaged • Inspect for damage. Service as required.
• Cylinder hub damaged or holes blocked • Inspect for damage. Service as required.
• Friction elements damaged, burnt • Inspect for damage. Service as required.
Intermediate Servo/Band Assembly
• Servo piston or bore damaged • Inspect for damage. Service as required.
• Band or drum burnt, damaged • Inspect for damage. Service as required.
T0119OO8
OTHER CONCERNS: NO ENGINE BRAKING IN MANUAL 1 POSITION ONLY

Main Controls
• 3-4 shift valve, low reverse clutch modulator valve, D2 valve, • Inspect for damage. Service as required.
4-3-2 timing valve, 2-3 shift valve, coast clutch shift valve
damaged, misassembled, stuck
• BS 1, CB 1 ball damaged, missing • Inspect for damage. Service as required.
• Reinforcing plate bolts loose • Retighten bolts to specification.
Coast Clutch Assembly
• Seal or piston damaged • Inspect for damage. Service as required.
• Stator support damaged or holes blocked, seal rings damaged • Inspect for damage. Service as required.
• Cylinder hub damaged or holes blocked • Inspect for damage. Service as required.
• Friction elements damaged, burnt • Inspect for damage. Service as required.
Low One-Way Clutch Assembly
• Friction elements damaged, worn • Inspect for damage. Service as required.
• Sealing area in case damaged • Inspect for damage. Replace case.
T0119018
OTHER CONCERNS: NO ENGINE BRAKING WITH OVERDRIVE CANCELLED

(MANUAL 1ST AND MANUAL 2ND HAVE ENGINE BRAKING)
control module, coast clutch solenoid Diagnosis Manual· for diagnosis. Perform Service Manual Pinpoint
Test "G" using the Transmission Tester 007-00a5C as outlined in
(Continued)

ALL RIGHTS RESERVED
OTHER CONCERNS: NO ENGINE BRAKING WITH OVERDRIVE CANCELLED

(MANUAL 1ST AND MANUAL 2ND HAVE ENGINE BRAKING) (Cont'd)
Main Controls
• Coast clutch solenoid damaged, stuck • Refer to electrical routine No. 260.
• BS2, BS3 check balls missing or valve body separator plate seat • Inspect for damage. Service as required.
damaged
• 3-4 shift valve stuck, damaged or misassembled • Inspect for damage. Service as required.
T0119028
OTHER CONCERNS: FLUID VENTING/FOAMING

• Vent blocked or damaged • Check vent for damage or blockage. Service as required.
• Overfilled transmission • Check level and adjust as required.
• Fluid contaminated (coolant, water) • Check for contamination, locate source of contamination. Service
as required.
• Overheating • Refer to Routine No. 257/357.
• Filter assembly and seal damaged or misassembled • Inspect filter assembly and seal for damage. Service as required.
• Pump to case gasket damaged, misaligned • Inspect for damage and replace.
T0119038
PRESSURE REFERENCE CHART DIAGNOSTIC ROUTINE NO. 401

Line Pressure Idle Stall
Gear KPA PSI KPA PSI
P 379-448 55-65 - -
R 517-683 ~
75-99 1655-1827 240-265
N 379-448 55-65 - -
00/0 379-448 55-65 1076-1200 156-174
2 379-448 55-65 1076-1200 156-174
1 517-683 75-99 1082-1282 157-186
CAUTION: Transtrllss10n Tester MUST BE REMOVED from the transmission and the Vehicle Harness reinstalled to verify these
pressures.
TO 125638

ALL RIGHTS RESERVED
Diagnostic Routine No. 501 Check Ball Locations
CB-7 CB-1 BS-3

EPC 0.25" STEEL
W/SPRING
PIN 353078-S
08.0 MM VITON (BALL)
PIN E7DP-7E195-AA
B8-1
CB-14
S1 AIR BLEED CB-9 S2 AIR BLEED D11905-C
CLUTCH/BAND APPLICATION CHART NO. 601

Friction Elements One-Way Clutches
Overdrive Intermediate Low
Inter-
medl- Inter-
ate Over- medl- For- Re-
Gear Band Coast Drive ate Direct ward verse Drive Coast Drive Coast Drive Coast
€) first - eb
- - - apply - HOLD eb
- - HOLD O/R
€) - eb
- apply - apply - HOLD eb
HOLD O/R O/R O/R
second
€) - eb
- apply apply apply - HOLD eb
O/R O/R O/R O/R
third
€) - - apply apply apply apply - O/R O/R O/R O/R O/R O/R
fourth
1 - apply - - - apply apply HOLD CC - - HOLD -
2 apply apply - apply - apply - HOLD CC HOLD BA O/R O/R
reverse - apply - - apply - apply HOLD CC O/R O/R - -
a In €) Range with the Transmission Control Switch pressed, the coast clutch is applied and the 0 I 0 one-way clutch is bypassed.
b On certain applications in 0 I 0 range, the cloast clutch solenoid and clutch is controlled by the PCM.
0/ D - Overdrive
OWC - One-Way Clutch
0/ R - Overrunning
CC - Coast Friction Clutch Applied
BA - Band Applied
TD15124A

ALL RIGHTS RESERVED
On-Board Diagnostic Quick Tests

CAUTION: Prior to performing any Quick Tests,
first perform the Preliminary Inspection and
Verification. Refer to the procedures in this
section.
The Quick Test procedures are also found in the
2
Powertrain Control/Emissions Diagnosis Manual.
These tests can be used to diagnose the powertrain
control module (PCM)( 12A650), sensors and
actuators of the E40D transmission.
The following is a guide for using the Quick Tests, with
some special considerations to remember.
Quick Test 1.0
Perform the Preliminary Inspection and Verification of
Condition. Refer to the procedures in this section.
Quick Test 2.0
NOTE: The On-Board Diagnostics can be entered only
once each time the ignition switch is turned on. To ARROW SYSTEM SWITCH
re-enter the On-Board Diagnostics, turn the ignition KEYS (SET IN EEC-IV POSITION)
switch off and wait 10 seconds. D10293-A
NOTE: Depending on the vehicle, On-Board
• Place system switch in the EEC-IV position.
Diagnostic Trouble Codes (DTCs) can either be
displayed in a two digit or three digit format. On • Tester in fast mode only (necessary to display
vehicles that display DTCs in the two digit format, three-digit codes).
either the Star or Super Star II Tester may be used. • Keep tester leads away from any moving parts.
However, on vehicles that display DTCs in the three
digit format, the Super Star II Tester must be used on • Deactivate Self-Test by making sure the button in
fast mode to properly display the DTCs. the middle is up. If not, press button once to unlatch.
Connect Rotunda Super Star II Tester 007-0041B or • Speaker switch on, if desired.
equivalent to Data Link Connector. • Turn tester to the ON position.
The following are procedures to run the EEC-IV CAUTION: Do not replace parts based on a code,
On-Board Diagnostics. perform Pinpoint Tests first.
All Tests Quick Test 3.0 Key On, Engine Off (KOEO)
NOTE: The On-Board Diagnostic can be entered only Some special considerations for Key On, Engine Off
once each time the ignition switch is turned to RUN. To (KOEO) On-Board Diagnostics include the following:
re-enter the On-Board Diagnostic, turn the ignition
switch off and wait 10 seconds. • The KOEO test provides both "hard" diagnostic
trouble codes (DTG) (present at the time of testing)
Vehicle and Super Star II Tester Preparation and continuous memory codes.
Prepare the vehicle as follows: • Always service the "hard" DTCs first. These
are displayed first on the tester.
• Transmission range selector lever in PARK
• On 7.3L diesel engines, the accelerator pedal must
• Engine to operating temperature be fully depressed for the entire KOEO test. DO
• Block wheels NOT depress the accelerator pedal for gasoline
• Turn off all electrical loads including A I C and engines.
defroster (if AIC is on, DTC 539 will set). Performing KOEO Self-Test
• Connect Rotunda Super Star II Tester 007-0041B or NOTE: If Super Star II Tester is unavailable, refer to
equivalent to the vehicle. Refer to Powertrain 2
2 the Powertrain Control/Emissions Diagnosis Manual
Control I Emissions Diagnosis Manual for specific for alternate methods to run the On-Board
vehicle test lead location. Diagnostics.
Prepare the Super Star II Tester as follows: NOTE: For diesel engines, before activating the
On-Board Diagnostic, the accelerator pedal must be
completely depressed to Wide Open Throttle and held
there for the entire KOEO On-Board Diagnostics.
1. Connect Super Star II Tester.
2. Activate On-Board Diagnostic by pressing center
button on Super Star II Tester.


ALL RIGHTS RESERVED
3. Turn ignition switch to ON position. b. The wiggle test allows the technician to
attempt to recreate an intermittent
4. Powertrain control module will run On-Board
malfunction. Tap, move and wiggle the
Diagnostics and then output "hard" DTCs (or
suspected sensor and / or wire harness.
Code 11 or 111-pass test). "Hard" DTCs are
When a malfunction is detected the Self Test
repeated to make it easier to verify sequence.
Output (STO) will be turned on as long as the
After "hard" DTCs have been repeated (or Code
concern is present. STO ON will cause the
11 or 111 repeated) a single pulse occurs to
Star Tester to sound a continuous tone. The
signal that next set of DTCs will be from
check engine malfunction indicator lamp will
continuous test (or Code 11 or 111-pass).
also illuminate.
5. To display codes unlatch center button and use
2. TP test mode (diesel engines only):
memory buttons to scroll through codes (Super
Star II - Fast Mode Only). a. Diesel engines also have a throttle position
sensor test mode that may be entered by
Quick Test 4.0 Continuous Memory Codes activating the transmission control switch.
CAUTION: DTCs in continuous memory can be This test is to check and adjust the sensor
erased by disconnecting the battery or by gauge block setting by monitoring the throttle
ungroundlng the Self Test Input CSTI) while the position sensor Self-Test Output with VRV
codes are being displayed during the KOEO Gauge Setting Block T92T-7B20Q-AH
On-Board Diagnostics. The STI is ungrounded by installed. For more information, refer to the
disconnecting the small Data Link connector or procedures outlined in this section.
unlatching the Star Tester button. Always write 3. Output cycling test mode:
down the DTCs to avoid losing Information that
can be used to diagnose the customer's concern. a. After all KOEO DTCs have been received,
the output test mode may be entered.
Continuous memory codes are from malfunctions Actuator outputs will turn ON and OFF each
which were detected during normal vehicle operation. time the throttle is depressed to Wide Open
These codes are retained for 40 warm up cycles. Throttle and then returned to closed position.
After servicing any KOEO or KOER "hard" DTCs and This allows checking of the voltage,
a pass code 11 or 111 is received on both, service the powertrain control module operation and
continuous memory codes. solenoid voltage.
Some special considerations for continuous testing Quick Test 5.0 Key On Engine Running (KOER)
include the following:
The Engine Running On-Board Diagnostic provides
• The cause of some continuous memory codes may "hard" DTCs only.
have been eliminated if KOEO and / or KOER DTCs Some special considerations for Key On Engine
were serviced. Always retest and service any DTCs Running (KOER) On-Board Diagnostics include the
that still remain. following:
• If DTCs are present, go to the Diagnostic Trouble
Code Description Chart in this Section for service • After the engine 10 code, push and release the
information. Service all non-transmission DTCs first brake pedal (2455).
as they can directly affect the operation of the • Push and release the transmission control switch.
transmission. Repeat the Quick Test and Road Test • If a DTC appears after the KOER test, a malfunction
to verify the correction. Erase DTC, perform drive is present. Refer to and look up the DTC on the
cycle and repeat the Quick Test after completing On-Board Diagnostic Trouble Code Description
service on the DTCs. Chart in this section for service information.
• If the continuous test passes (11 or 111) and a
concern is still present, refer to the Diagnosis by . Performing KOER Self-Test
Symptom charts, Oasis and TSBs for concern NOTE: Engine must be warm or DTC 21 or 116 -
diagnostics. ECT out of On-Board Diagnostic range will occur.
Special Test Modes 1. Connect Super Star II Tester.
1. Wiggle test mode: 2. Start and run engine until operating temperature
is reached.
a. After all OTCs have been received the wiggle
test may be entered by pressing the center 3. Turn engine OFF and wait 10 seconds.
button on Star Tester twice. This will unlatch 4. Activate On-Board Diagnostics (press center
and relatch STI. button on Star Tester).

ALL RIGHTS RESERVED
5. NOTE: With RPM sensor failures you may not Special Test Mode
receive a Code "50" 10. The On-Board 1. Wiggle test mode:
Diagnostics will run KOEO instead of KOER; if
test is interrupted DTCs may be lost. a. After all DTCs have been received the wiggle
test may be entered by pressing the center
Start engine. button on Star Tester twice. This will unlatch
a. On-Board Diagnostics begin when the engine and relatch STI.
10 code is received. (This code consists of The wiggle test allows the technician to attempt to
the number of cylinders divided by 2 plus an recreate an intermittent malfunction. Tap, move and
. added zero).
wiggle the suspected sensor and / or wire harness.
b. Example: a four-cylinder would be divided by When a malfunction is detected the STO will be turned
2=2 plus an added 0 would = 20. A on as long as the concern is present. STO ON will
six-cylinder would be a code of 30. An cause the Star Tester to sound a continuous tone. The
eight-cylinder would be a code of 40. check engine lamp will also illuminate.
c. On the 7.3L diesel engine, a Code" 50" Quick Test 6.0 Computed Timing Check
should appear on the "Engine 10" display. If
this does not appear, allow the test to This Quick Test is used to diagnose engine idle
complete. Repeat On-Board Diagnostics. If concerns only. Refer to the Powertrain
the Code "50" still does not appear, go Control I Emissions Diagnosis Manual for procedures.
directly to the Pinpoint Tests in the Any engine concerns or DTCs should be serviced
appropriate year Powertrain BEFORE the transmission concerns are serviced.
3
Control/Emissions Diagnosis Manual for Test Procedures with NGS
Engine RPM Sensor (Diesel).
NOTE: NGS must be used on EEC-v equipped vehicles
d. After the 10 code is received, the technician in order to properly retrieve 4 digit DTC's.
must cycle the Transmission Control Switch.
Then press and release the brake pedal. The Quick Tests are in the Powertrain
Control/Emissions Diagnosis Manual (PC/ED). These
e. A signal output pulse (10) is sent to signal the test can be used to diagnose the powertrain control
technician to quickly press the throttle to module, sensor and actuators of the 4R70W
wide open and immediately release. Super transmission.
Star II Tester will display the word Dynamic
response (gas engine only). The following is a guide for using the On-Board
Diagnostic (OBD) Quick Tests and the New
f. DTCs are then sent (or Code 11 or 111-pass Generation Star Tester (NGS), with some special
test). considerations to remember:
g. CAUTION: DTCs in continuous memory NOTE: For detailed instructions and other diagnostic
can be erased by disconnecting the methods using the NGS, refer to the PC / ED Manual or
battery or by ungrounding the Self-Test NGS instruction guide.
Input (STI) while the codes are being
displayed during KOEO On-Board NOTE: If using a generic scan tool, refer to the PC/ED
Diagnostics. The STI is ungrounded by Manual for instructions on performing OBD
disconnecting the small data link procedures.
connector or unlatching the Super Star II Quick Test 1.0
center button. Always write down the
Perform the Visual Check and Vehicle Preparation
DTCs to avoid losing information that can
procedures as outlined irtthe Powertrain
be used to diagnose the customer
Control/Emission Diagnosis Manual.
concern.
Inspect the following:
To display codes using a Super Star II tester,
unlatch the center button and use the • Air Cleaner and inlet ducting.
memory buttons to scroll through the codes
Super Star II - Fast Mode. • All engine vacuum hoses for damage: leaks, cracks,
blockage, proper routing, etc.
h. If a DTC appears after the KOER test, a
malfunction is present. Refer to the EEC-IV • PCM System wiring harnesses for proper
On-Board Diagnostic Trouble Code connections, bent or broken pins, corrosion, loose
Description Chart in this section for service wires, proper routing, etc.
information. • PCM, sensors and actuator for physical damage.
6. The Engine Running wiggle test may be entered • Engine coolant for proper level..
upon completion of the Engine Running On-Board • Transmission fluid for proper level and condition.
Diagnostics by pressing the center button on the
Super Star II Tester twice. This will "unlatch" and • Any NON-Factory installed items wired into the
"relatch" STI, activating the wiggle test mode. transmission or PCM harnesses.


ALL RIGHTS RESERVED
NOTE: Perform all necessary servicing before CAUTION: Do not replace parts based on a code,
continuing with Quick Tests. perform Pinpoint Tests first.
Quick Test 2.0 Quick Test 3.0 Key On, Engine OFF (KOEO)
Connect New Generation Star Tester 007-00500 or Some special considerations for Key On, Engine Off
equivalent to Data link Connector (refer to vehicle Quick Test include the following:
owners manual for location).
• The KOEO test provides "hard" Diagnostic Trouble
The following are procedures to run OBDn procedures. Codes (DTCs) present at the time of testing.
Vehicle Preparation and New Generation Star • Always service the "hard" DTCs first.
Tester Preparation Performing KOEO Quick Test
Prepare the vehicle as follows:
• Perform visual inspection and vehicle preparation as
• Transmission Range Selector lever in PARK. required.
• Engine to operating temperature. • Select "Vehicle and Engine Selection" menu.
• Apply parking brake. • Select year, engine, model with the appropriate
qualifier if needed, for example, transmission or 49
• Block wheels.
state/cal.
• Turn OFF all electrical loads including A / C and
defroster. (If A/C is ON, DTC P1460 will set). • Select "Diagnostic Data link" menu.
• Select "Diagnostic Test Mode" menu.
Prepare the NGS 8S follows: • Select "KOEO On-Demand Self-Test".
• Follow operating instructions from the NGS menu
PROGRAM CARD screen.
(INSERT INTO BACK OF
LCD SCREEN CONTROL UNIT) • Record all DTCs displayed.
• Service NON-Transmission DTCs first as they can
directly affect the operation of the transmission.
Road Test and repeat Quick Test to verify the
repair.
Quick Test 4.0 Continuous DTCs Codes
Continuous DTCs are concerns which were detected
during normal vehicle operation. These codes are
retained for 40 warm up cycles.
Some special considerations for Continuous DTC
testing include the following:
• The cause of some Continuous DTC's may have
been eliminated if KOEO and / or KOER DTCs were
serviced. Always retest and service any DTCs that
still remain.
• If DTCs are present, go to the On-Board DTC
D12116-A Description Chart in this section for service
information. Erase DTC, perform the Transmission
• KeyOFF. Drive Cycle and repeat all Quick Test procedures
• Verify that the proper PROGRAM card is inserted in after completing service on the OTCs.
theNGS. • If the Continuous Tests passes (P1111) and a
• Connect J 1962 / 16 way DCl cable adapter to the concern is still present refer to the Diagnosis by
NGS. Symptom Charts, Oasis and TSBs for concern
diagnosis.
• Connect NGS DCl cable adapter securely into the
vehicles DCl connector. Peforming Continuous DTC Tests
• Connect the NGS power supply cable to the vehicle • Select "Vehicle and Engine Selection" menu
battery power supply through cigarette lighter or at
the battery with alligator clip adapter. • Select year, engine, model with the appropriate
qualifier if needed, for example, transmission or 49
• Key On or start vehicle if necessary. state/cal.
• The NGS is now ready to communicate with the • Select "Diagnostic Data Link" menu.
PCM.
• Select "Retrieve Continuous Codes".

ALL RIGHTS RESERVED
DIAGNOSIS AND T~STING (Continued)
• Follow operating instructions from the NGS menu • Enter "Output Control".
screen.
• Record all DTCs displayed. screen.
• Perform Transmission Driv Cycle Test. PCM Reset Mode (Clearing DTCs)
• Rerun Continuous DTC Test, if DTCs have returned
The PCM RESET Mode provides a means for the NGS
service as required. Road Test and rerun all DTCs
to command the PCM to clear all DTCs. When
test procedures.
resetting the PCM, a DTC No. P1000 will be set in the
Quick Test 5.0 Key On Engine Running (KOER) PCM until all OBOII System or components have been
monitored during the OBOII Drive Cycle. The following
The Engine Running Quick-Test provides "hard" DTCs
only. list is what happens ~hen a PCM reset is performed.
Some special considerations for KOER Quick-Test • Clears the OTCs.

include the following: • Clears the Freeze Frame Data.
• Follow the menu screen instructions as they appear. • Clears the Oxygen Sensor Test Data.
• If a DTC appears after the KOER test, a malfunction • Resets the Status of the OBOII System Monitors.
is present. Refer to the DTC Code Chart for service • Sets the DTC No. P1000.
information.
Performing the PCM RESET:
Performing the KOER Test
• Perform visual inspection and vehicle preparation as
• Perform visual inspection and vehicle preparation as required.
required.
• Select "Vehicle and Engine Selection" menu.
• Select "Vehicle and Engine Selection menu.
• Select year, engine, model with the appropriate
• Select year, engine, model with the appropriate qualifier if needed, for example, transmission or 49
qualifier if needed, for example, transmission or 49 state/cal.
state/cal.
• Select "Generic OBDII Functions" menu.
• Select "Diagnostic Data Link menu.
• Select "Clearing ALL Codes".
• Select "KOER On-Demand Self-Test". screen.
• Follow operating instructions from the NGS menu • Perform OBDII Drive Cycle - Clear No. P1000.
screen (example: turn key on, etc) and perform
Brake On / OFF (BOO) and cycle the Transmission Clearing DTC No. P1000 Procedures
Control Switch (TCS) on and off, if equipped. Readiness for Inspection / Maintenance Testing
• Record all DTCs displayed. In some localities it may become a legal requirement to
• Service all NON-Transmission DTCs first as they pass an Inspection / Maintenance (1/ M) test of the
can directly affect the operation of the transmission. OBDII System. If the vehicles powertrain system or its
Road Test and repeat Quick Test to verify repair. battery has just been serviced, the OBOII system is
reset to a not ready for I / M testing condition. To
Output Test Mode prepare the vehicle for this test and to clear the DTC
The Output Test Mode (OTM) aids is servicing output No. P1000 the OBDII Drive Cycle must be performed.
actuators associated with the PCM system. It allows 08DII Drive Cycle
the technician to energize and de-energize most of the
The following steps MUST BE RUN IN THE ORDER
system output actuators on command.
SHOWN. If steps 2, 3, or 4 is interrupted, repeat the
Performing the Output Test Mode (OTM) step before proceeding. Any safe driving mode is
:i acceptable between steps.
You must enter OTM with ignition key ON and the
engine OFF. Always drive vehicle in a safe manner according to
traffic conditions and obey all traffic laws.
• Perform visual inspection and vehicle preparation as 1. Start engine and drive vehicle in typical city stop
required. and go traffic for at least 10 minutes after it has
• Select "Vehicle and Engine Selection" menu. reached normal operating temperature.
• Select year, engine, model with the appropriate 2. Idle vehicle for at least 45 seconds, then
qualifier if needed, for example, transmission or 49 accelerate at part throttle to near 45 MPH.
state/cal. 3. Cruise and maintain a select speed in the range of
• Select "Diagnostic Data Link" menu. 30 to 40 MPH on a level road with throttle held
steady for at least one (1) minute.
• Enter" Active Tests" .
ALL RIGHTS RESERVED
4. Then drive to accumulate at least 4 minutes in the 6. With transmission in fourth gear and maintaining
range of 20 to 45 MPH. If stop and go conditions steady speed and throttle opening, lightly apply
occur, the designated accumulative time must be and release brake pedal (2455) (to operate
within the 20 to 45 MPH range. No Wide OPEN stoplamps). Then hold speed and throttle steady
Throttle (WOT) conditions should be for an additional five seconds (minimum).
encountered. 7. Brake to a stop and remain stopped for a
5. Decelerate and idle for at least 10 seconds. minimum of 20 seconds.
6. Accelerate to approach 55 MPH at 1/2 throttle 8. Repeat Steps 4 through 6 at least five times.
(elapsed time is about 10 seconds). 9. Perform Quick Test and record continuous codes.
7. Cruise and maintain select speed in the range of
40 to 65 MPH on a level road with throttle held
steady for at least 1 minute and 20 seconds.
8. OBDII Drive Cycle has been completed. After On-Board Diagnostics
Other NGS Testing Features After the On-Board Diagnostics procedures are
completed, service all DTCs.
For further information on other diagnostic testing
features using the NGS or generic scan tool, refer to Begin with non-transmission related DTCs, then
the PC / ED Manual. Other diagnostic methods include service any transmission related DTCs. Refer to the
the following: On-Board Diagnostic Trouble Code Description Chart
for information on Condition and Symptoms. This chart
• Parameter Identification (PID) Access Mode, used will be helpful in referring to the proper manual(s) and
to monitor sensor and actuators. to aid in diagnosing internal transmission concerns and
• Freeze Frame Data Access Mode, used to view external non-transmission inputs. The Pinpoint Tests
emissions related data values from specific PIDs. are used in diagnosing electrical concerns of the
E40D transmission. Make sure that the vehicle wiring
• Oxygen Sensor Monitor Mode, used to monitor the harness and the powertrain control module
02 sensor. (PCM)( 12A650) are diagnosed as well. The
Powertrain Control/Emissions Diagnosis Manual4 will
aid in diagnosing non-transmission electronic
components.
Transmission Drive Cycle Test NOTE: The vehicle wiring harness, powertrain control
NOTE: The Transmission Drive Cycle Test must be module and non-transmission sensors may affect
followed exactly. Malfunctions have to occur four transmission operations. Service these concerns first.
times consecutively for codes 49,59,617,618, and
619 to be set, and five times consecutively for Before Pinpoint Tests
continuous code 62 or 628. NOTE: Prior to entering Pinpoint Tests, check the
After performing the Quick Test, use the following powertrain control module wiring harness for proper
Transmission Drive Cycle Test for checking E40D connections, bent or broken pins, corrosion, loose
continuous codes: wires, proper routing, proper seals and their condition.
Check the powertrain control module, sensors and
NOTE: When performing the Drive Cycle Test, refer to actuators for damage. Refer to the Powertrain
the Solenoid Application Chart for proper solenoid Control/Emissions Diagnosis Manual. 4
operation. Refer to the Table of Contents.
If DTCs appear while performing the On-Board
1. Record and then erase Quick Test codes. Diagnostics refer to the On-Board Diagnostic Trouble
2. Warm engine to normal operating temperature. Code Description Chart for the appropriate service
procedure. Prior to entering Pinpoint Tests, refer to
3. Make sure transmission fluid level is correct. any TSBs and Oasis messages for E40D transmission
4. With transmission in DRIVE, press Transmission concerns.
Control Switch (LED lamp should illuminate) and NOTE: After Electrical Diagnosis has been performed
moderately accelerate from stop to 64 Km/H (40 and a concern still exists, refer to the Diagnosis by
mph). This allows transmission to shift into third Symptom charts in this section.
gear. Hold speed and throttle opening steady for
a minimum of 30 seconds.
5. Press TCS (LED lamp should turn off) and
accelerate from 64 Km / h (40 mph) to 80 Km / H
(50 mph). This allows transmission to shift into
fourth gear. Hold speed and throttle position
steady for a minimum of 30 seconds.


ALL RIGHTS RESERVED
On-Board Diagnostic Trouble Code

Description Chart
Diagnostic Trouble
Code
Four Three
Digit Digit Component Description Condition Symptoms/Actions
P1111 111 System Pass No concern detected. Concern not detected by powertrain
control module-b
P0340 211 Crankshaft Crankshaft position sensor Engine RPM circuit failure. Crankshaft position sensor
P0341 position sensor concern. failure / engine will stall or not run.)
P0344 May flash transmission control
indicator lamp. b
- 126 Manifold Manifold absolute Manifold absolute Rerun On-Board Diagnostics.
absolute pressure sensor out of pressure sensor signal
pressure On-Board Diagnostics higher or lower than
sensor range. expected or no response
during Dynamic Response
(Goose) Test.
- 128 Manifold Manifold absolute Manifold absolute Firm shift fell, late shifts at altitude. b
absolute pressure sensor vacuum pressure sensor signal
pressure circuit failure. higher or lower than
sensor expected or no response
during Dynamic Response
(Goose) Test.
- 121 Throttle Throttle position sensor Throttle position sensor Rerun at appropriate throttle position
Position out of On-Board (gasoline engines) not at sensor position per the engine
Sensor Diagnostics range. idle position during KOEO. application. May flash transmission
P1781 633 4x4Low 4x4 Low switch closed. 4x4 Low switch closed / or Failed on - Early shift schedules in
Switch 4x4 Low indicator lamp 4x2 and 4x4 HI range.
circuit open. Failed off - Shifts delayed in 4x4
Low.
NOTE:lf the 4x410w indicator light
fuse is blown, the transmission will
shift according to the 4x4 Low shift
schedule regardless of the transfer
case position.-
P1729 691 4x4L 4x4 Low switch failure. 4x4 low switch failure Early shifts, harsh shifts, Increase in
during normal vehicle electronic pressure control
operation. pressure.-
P1711 636 Transmission Transmission fluid Transmission not at Warm vehicle to normal operating
Fluid temperature sensor out of operating temperature temperature and rerun On-Board
Temperature On-Board Diagnostics during On-Board Diagnostics.
Sensor range. Diagnostics.
P0500 452 Vehicle Speed Insufficient vehicle speed Powertrain control module Harsh engagements, firm shift feel,
Sensor input. detected a loss of vehicle abnormal shift schedule, unexpected
speed signal during downshifts may occur at closed
operation. throttle, abnormal torque converter
clutch operation or engages only at
Wide Open Throttle. May flash
transmission control indicator lamp.-
P0781 c 617c Shift Solenoid 1-2 shift error. Engine RPM drop not Improper gear selection depending on
1, Shift detected when 1-2 shift failure mode and transmission range
Solenoid 2 or was commanded by selector lever position. Refer to Shift
Internal powertrain control module Application Chart. Shift errors may
Transmission also be due to other internal
Components transmission concerns such as stuck
valves or damaged friction material.
May flash transmission control
indicator lamp.
Refer to Pinpoint Test A.
(Continued)

ALL RIGHTS RESERVED
Diagnostic Trouble
Cod.
Four Three
P0123 123 Throttle Throttle position sensor or Voltage above or below Harsh engagements, firm shift feel,
Position accelerator pedal position specification for On-Board abnormal shift schedule, abnormal
Sensor or sensor circuit above Diagnostics or during torque converter clutch operation or
accelerator maximum voltage, (short normal vehicle operation. does not engage. May flash
pedal position to vehicle power). transmission control indicator lamp. b
sensor
P0713 637 Transmission -40°C (-40°F) indicated, Voltage drop across Torque converter clutch and
Fluid transmission fluid transmission fluid stabilized shift schedule may be
Temperature temperature sensor circuit temperature sensor enabled sooner after cold start.
Sensor open. exceeds scale set for Refer to Pinpoint Test B.
temperature -40 °C
(-40°F).
P0782c 61Sc Shift Solenoid 2-3 shift error. Engine RPM drop not Improper gear selection depending on
Internal powertrain control module Application Chart. Shift errors may
indicator lamp.
P1728 62Sc Transmission Transmission slippage Excessive amount of Transmission slippage, erratic or no
detection. clutch slippage was torque converter clutch operation.
detected. May flash transmission control
indicator lamp.
Refer to Diagnosis by Symptom.
P0122 122 Throttle Throttle position sensor or Voltage above or below Harsh engagements, firm shift feel,
Position accelerator pedal position specification for On-Board abnormal shift schedule, abnormal
Sensor or sensor circuit below Diagnostics or during torque converter clutch operation or
accelerator minimum voltage, normal vehicle operation. does not engage. May flash
pedal position (open I shorted to ground). transmission control indicator lamp. b
sensor
- 124 Throttle TP sensor voltage higher Voltage above Harsh engagements, firm shift feel,
Position than expected. specification. abnormal shift schedule, abnormal
Sensor torque converter clutch operation or
does not engage. May flash
- 125 Throttle TP sensor voltage lower Voltage below Harsh engagements, firm shift feel,
Position than expected. specification. abnormal shift schedule, abnormal
Sensor torque converter clutch operation or
does not engage. May flash
P1780 632 Transmission Transmission control Transmission control Rerun diagnostics and cycle switch.
Control Switch switch not changing state. switch not cycled during No overdrive cancel when switch is
On-Board cycled.-
Diagnostics I circuit open
or shorted.
P0712 638 Transmission 157°C (315°F) indicated, Voltage drop across Torque converter clutch and
Fluid transmission fluid transmission fluid stabilized shift schedule may be
Temperature temperature sensor circuit temperature sensor enabled sooner after cold start.
Sensor grounded. exceeds scale set for Refer to Pinpoint Test B•.
temperature of 157°C
(315°F).
P1460 539 Air A I C switch error. Diagnostic Trouble Code Failed on - electronic pressure
P1463 Conditioning may result from A/C clutch control pressure slightly low with A I C
P1464 Clutch being "ON" during off.
On-Board Diagnostics. Failed off - electronic pressure
control pressure slightly low with A I C
on.-
(Continued)

ALL RIGHTS RESERVED
Diagnostic Trouble
Code
Four Three
- 654 Transmission Transmission Range (TR) On-Board Diagnostics not Rerun On-Board Diagnostics in park.
Range (TR) Sensor not in park. run in park.
Sensor
P0705 634 Transmission Transmission Range (TR) Indicated voltage drop Harsh engagements, firm shift feel.
Range (TR) Sensor out of range. across Transmission Refer to Pinpoint Test D.
Sensor Range (TR) Sensor
exceeds limits established
for each position.
P1783 657 Transmission Transmission Overtemp Transmission fluid Slight increase in electronic pressure
Fluid Condition. temperature exceeded control pressure. May flash
Temperature 270°F. transmission control indicator lamp.
Sensor Refer to Pinpoint Test B.
P1706 659 Transmission Transmission Range (TR) Transmission Range (TR) Electronic pressure control pressure
Range (TR) Sensor indicating park Sensor indicating park high, all shifts firm
Sensor during operation. during operation. Refer to Pinpoint Te.st D.
P0707 667 Transmission Transmission Range (TR) Transmission Range (TR) Increase in electronic pressure
Range (TR) Sensor circuit below Sensor circuit or control pressure
Sensor minimum voltage. powertrain control module Refer to Pinpoint Test D.
shorted or grounded.
P0708 668 Transmission Transmission Range (TR) Transmission Range (TR) Increase in electronic pressure
Range (TR) Sensor circuit above Sensor, circuit or control pressure
Sensor maximum voltage. powertrain control module Refer to Pinpoint Test D.
indicates open.
- 157,158, Mass Airflow Mass airflow sensor Mass airflow sensor High- electronic pressure control
159,184, Sensor diagnostic trouble codes. system has a malfunction pressure. Firm shifts and
185 which may cause a engagements. May flash transmission
transmission concern. control indicator lamp.
Refer to Powertraln
Control/Emissions Diagnosis
manual.-
P0107 - Baro Sensor Baro Sensor circuit failure. Barometric pressure Firm shift fell, late shifts at altitude. b
sensor signal lower than
expected.
P0108 - Barometric Baro Sensor circuit failure. Barometric pressure Firm shifts, late shifts at altitude. b
pressure sensor signal higher or
sensor lower than expected.
P1280 - Injector control ICP sensor circuit failure. Open / Grounded circuit, May result in firm shifts. Refer to 7.3L
pressure Out of range low. biased sensor or PCM. 01 PC/ED manual.
sensor
P1281 - Injector control ICP sensor circuit failure. Short circuit to 5 volt Ref., May result in firm shifts. Refer to 7.3L
pressure Out of range high. biased sensor or PCM. 01 PC/ED manual.
sensor
P0783c 619 d Shift Solenoid 3-4 shift error. Engine RPM drop not Improper gear selection depending on
Jlnternal powertrain control module. Application Chart. Shift errors may
indicator lamp.
- 129 Manifold Insufficient manifold Manifold absolute Rerun On-Board Diagnostics and
absolute absolute pressure sensor pressure sensor signal perform Dynamic Response Test.
pressure change dynamic response higher or lower than
sensor test (gasoline engines expected or no response
only). during Dynamic Response
(Goose) Test.
(Continued)

ALL RIGHTS RESERVED
Dlagn08tlc Trouble
Code
Four Three
Digit Digit Component De8crlptlon Condition Symptome/Actlone
- 167 Throttle Insufficient throttle Throttle not depressed Rerun On-Board Diagnostics and
Position position sensor change during KOER. depress (goose) throttle when
Sensor dynamic response test. indicated.
P1703 536 Brake On / Off Brake not actuated during Brake not cycled during Failed on or not connected - Torque
Switch On-Board Diagnostics. KOER. converter clutch will not engage at
less than 1/3 throttle.
Brake on / off switch circuit Brake on / off circuit failure. Failed off - Torque converter clutch
failed. will not disengage when brake is
applied.-
P0750d 621 d Shift Solenoid Shift solenoid circuit Solenoid 1 circuit failed to Improper gear selection depending on
1 failure. provide voltage drop failure mode and transmission range
across solenoid. Circuit selector lever position. Refer to Shift
open or shorted or Solenoid Application Chart.
powertrain control module Refer to Pinpoint Teet A.
driver failure during KOEO.
P0755d 622c Shift Solenoid Shift Solenoid 2 solenoid Solenoid 2 circuit fails to Improper gear selection depending on
2 circuit failure. provide voltage drop failure mode and lever position. Refer
across solenoid. Circuit to the Shift Solenoid Application
open or shorted or Chart.
powertrain control module Refer to Pinpoint Teet A.
1754d 626d Coa$t Clutch Coast clutch solenoid Coast clutch solenoid Failed off - No third gear engine
Solenoid circuit failure. failed to provide voltage braking in overdrive cancel.
drop across solenoid. Failed on - Third gear engine
Circuit open or shorted or braking in overdrive range. Coast
powertrain control module Clutch may be damaged / eventual
driver failure during KOEO. failure.
Refer to Pinpoint Teet F.
P0743d 627 d Torque Torque converter clutch Torque converter clutch Short cirQuit - Engine stalls in Drive
629d Converter solenoid circuit failure. solenoid circuit fails to or manual 2 at idle with brake applied.
Clutch provide voltage drop Open circuit - Torque converter
Solenoid across solenoid. Circuit clutch never engaged.
open or shorted or Refer to Pinpoint Teet C.
powertrain control module
P1779 631 Transmission Transmission control Transmission control Failed on - Overdrive cancel mode
Control indicator lamp circuit indicator lamp circuit open always indicated, no flashing for
Indicator Lamp failure. or shorted. electronic pressure control failure.
Failed off - Overdrive cancel mode
never indicated, no flashing for
electronic pressure control failure.·
P1747 624d Electronic Electronic pressure Voltage through electronic Short circuit - (Gasoline engines):
Pressure control circuit failure, pressure control circuit is Causes minimum electronic pressure
Control shorted circuit or checked and compared control pressure (minimum capacity).
powertrain control module. after a time delay. An error Limits engine torque (partial fuel
will be noted if tolerance is shut-off, heavy misfire). Flashing
exceeded during KOEO transmission control indicator lamp.
and continuous On-Board Diesel engines - Harsh
Diagnostics. engagements and shifts, flashing
Open circuit - (Gasoline and diesel
engines): Causes maximum
electronic pressure control, harsh
engagements and shifts. May flash
Refer to Pinpoint Teet E.
(Continued)

ALL RIGHTS RESERVED
Diagnostic Trouble
Code
Four Three
P1746 d 625 d Electronic Powertrain control module Voltage through electronic Short circuit - (Gasoline engines):
Pressure failure - electronic pressure control circuit is Causes minimum electronic pressure
Control pressure control driver. checked and compared control pressure (minimum capacity).
after a time delay. An error Limits engine torque (partial fuel
will be noted if tolerance is shut-off, heavy misfire). Flashing
exceeded during KOEO transmission control indicator lamp.
and continuous On-Board Diesel engines. Harsh engagements
Diagnostics. and shifts, flashing transmission
Open circuit - (Gasoline and diesel
engines): Causes maximum
electronic pressure control, harsh
engagements and shifts. May flash
Aefer to Pinpoint Test E.
a Refer to Powertrain Control/Emissions Manual; may be purchased as a separate item.
b Refer to the appropriate section in this manual.
c Output circuit check, generated only by electrical conditions.
d May also be generated by other non-electronic related transmission hardware condition.
Rotunda Transmission Tester 3. Solenoid Activate Buttons: Energize

Use Rotunda Transmission Tester 007-Q085C or respective solenoids during click testing and
equivalent to diagnose electronically controlled activate selected circuits during DRIVE mode
transmissions (7003). The following instructions testing.
outline the set-up and use of this tester in the pinpoint 4. Bench/Drive Switch: Selects operating mode,
'tests for the E40D. either BENCH or DRIVE.
Tester Jacks 5. Solenoid Select/Gear Select Switch: Has
three functions:
1. VPWR Pin Jacks (red): Vehicle Power (VPWR)
test points for solenoid circuits. • In BENCH MODE: acts as shift solenoid
2. Solenoid (TCC, EPC) Signal Line Pin Jacks selector for click testing.
(black): Signal line test points for solenoid • In DRIVE MODE: acts as forward gear selector
circuits. in place of vehicle's powertrain control module
3. BAT + (red) and BAT - (black) Pin Jacks: (PCM)(12A650) controlled shifting. Hydraulic
Battery reference points when measuring circuits safety mechanisms and overrides are built into
for shorts. the transmission.
4. TFT Pin Jacks: Test points for transmission fluid • In OHMS CHECK: allows you to measure
temperature sensor. ohms.
Tester LEOs and Controls

1. Overlay and Cable Correctly Installed LEOs:
Only LEDs with symbol and cable correctly
match.
~
2. Status LEOs: LED OFF when not activated by
tester (solenoid not activated, open circuit or
signal line short to ground). LED uGREEN" when
activated by tester and current draw is correct.
LED "RED" when activated by tester and current
draw is excessive (short to Battery Positive
Voltage [B+ ]). All LEDs light orange during
On-Board Diagnostic.
ALL RIGHTS RESERVED
Transmission Tester Instructions

NOTE: The Rotunda Transmission Tester 007-00a5C
or equivalent must be used to perform the Pinpoint EEC·IV 6o-WAY
12·WAY CONNECTOR PIN
Tests. CONNECTOR DESCRIPTION 4.7l (CAlIf)
PIN GAS DIESEL 5.0L
5.8l (CALif)
1 VEHICLE POWER (VPWR) 37.57 71.97 37.57
TRANSMISSION TESTER
~ <y? ~ 4
TOROUE
53 28 53
( + + + E40D-'95/ ] CONVERTOR CLUTCH
COAST CLUTCH
TCC ccs EPC 5
SOLENOID
55 28 55
6
+ + + + + +
VPWRI STATUS TRANSMISSION OIL
VPWR STATUS VPWR STATUS 7 42 37 49
EPC PWR TEMPERATURE SENSOR
ACTIVATE ACTIVATE SIGNAL RETURN
ACTIVATE 8 46 91 46
(SIG RTN)
+ + + + + +
CCC CCS EPC 9
10
SHiFf SOLENOIDS ELECTRONIC PRESSURE
11 38 91 38
V~WR
CONTROL
S;.1'1 STATUS 1 2 3 4
L+~~~~
ELECTRONIC PRESSURE
12 37.57 71.97 37,57
CONTROL POWER
V;WR s~ + ~IGAEENIIGAEENICQE:
L.- GEAR SELECT --.J
12-WAY CONNECTOR
TRANSMISSION END HARNESS END
CLICK TEST PIN 1
+
SOLENOID SELECT
!ACTIVATEL- SS.' $$-2 OHMS
BENCH \ \ )HECK "NOT USED
+ MODE +
+
~
DRIVE
/"\"
,-- 1 I \ lNOTE:GEAR
SHIFT LEVER
GEAR SELECT 2 3 IN @
I
CJ
FT EXT POWER
+ + + + PIN 7 PIN 6 PIN 6 PIN 7
+ - BAT + BAT-
PART No. 3122-766
NOTE: BOTH VIEWS ARE "LOOKING INTO"
D10070-B D11838-C
Transmission Tester Use

The Rotunda Transmission Tester 007-00a5C or
equivalent allows a technician to operate the electrical
portion of the transmission independent of the vehicle
electronics which allows the technician to determine
transmission concerns. The Transmission Tester
usage is divided in five steps:
• Preliminary Testing and Diagnosis
• Installing the Transmission Tester
• Static Testing - Vehicle Running
• Dynamic Testing - Vehicle Running
• Removing Transmission Tester and Clearing DTCs
Preliminary Testing and Diagnosis
Before any diagnostic testing is done on vehicle some
preliminary checks must be performed, as outlined
below. Be sure to write down findings, especially any
DTCs found, for future reference.
a. Check transmission fluid level and condition.
b. Check for add-on items (phones, computers, CB
radio, etc.).
ALL RIGHTS RESERVED
c. Visually inspect wiring harness and connectors. Static Testing - Engine Off
d. Check for vehicle modifications. Static testing procedures allow for shop testing of the
e. Check shift linkage for proper adjustment. transmission in the vehicle or on the bench.
Completion of these tests prove out transmission
f. Verify customer concern: electronics.
- Upshift, Downshift, Coasting, Engagement, CAUTION: For resistance checks, be sure the
Noise / Vibration. tester solenoid select switch is set to the OHMS
g. Vehicle must be at normal operating temperature. CHECK position or damage to the ohmmeter may
result.
h. Perform vehicle On-Board Diagnostics.
Resistance/Continuity Tests
i. Record all DTCs.
j. Service all non-transmission codes. • Using a digital volt-ohmmeter and the transmission
tester perform the Pinpoint Tests as indicated
Transmission Tester Installation (Set-Up based on the DTCs which were displayed.
Procedure) • Service as indicated by the pinpoint tests. Always
Installing the transmission tester at the transmission retest and road test vehicle after service.
connector allows separation of the vehicle electronics
from transmission electronics. Disconnecting normal Transmission Solenoids and Sensors
vehicle electronics will set additional codes and cause Resistance Tests
firm shifts. (Disconnecting the transmission connector EPC Solenoid
defaults transmission to maximum line pressure).
NOTE: During tester usage additional DTCs may be • Set ohmmeter to 100-200 ohm range.
set. Therefore, it is important that all codes are erased • Connect negative lead of ohmmeter to the
after service has been made. To verify elimination of electronic pressure control (EPC) jack.
all codes rerun On-Board Diagnostics. • Connect positive lead of ohmmeter to the vehicle
NOTE: The following manuals should be available to power (VPWR) jack.
assist in diagnosis of electronically controlled • Record resistance.
transmissions:
• Refer to the following charts for values.
- Powertrain Control/Emissions Diagnosis Manual. 5
If out of specification, refer to Pinpoint Test E in this
- Transmission Tester Manual (provided with Section.
tester).
Shift Solenoid 1, Shift Solenoid 2, Torque
1. CAUTION: Do not attempt to pry off Converter Clutch Solenoid, Coast Clutch
connectors with a screwdriver. This will Solenoid
damage the connector and could result in
transmission concerns. If vehicle is equipped • Set ohmmeter to 100-200 ohm range.
with transmission heat shields (7A434),
remove them. Always replace transmission • Connect positive lead of ohmmeter to the
appropriate vehicle power (VPWR) jack for the
heat shields after service.
solenoid being tested.
CAUTION: Route all cables away from heat
sources. • Connect negative lead of the ohmmeter to the
appropriate solenoid (shift solenoid 1 [SS 1], shift
Disconnect vehicle wiring harness at solenoid 2 [SS2], torq.ue converter solenoid [TCC],
transmission connector. coast clutch solenoid LCCC]) jack and record
2. Turn tester solenoid select switch to the OHMS resistance.
CHECK position. Refer to following charts for values.
3. Install appropriate overlay onto tester. Connect If out of specification, refer to Pinpoint Test A (Shift
appropriate interface cable to transmission tester Solenoid 1, Shift Solenoid 2); Pinpoint Test C (Torque
and then to the appropriate transmission Converter Solenoid), Pinpoint Test G (Coast Clutch
connectors. Solenoid).
4. CAUTION: Route gauge line away from heat
sources. Transmission
Install a line pressure gauge into line pressure tap Application
on transmission. E40D
Solenoid
5. Plug transmission tester power supply into cigar Resistance
lighter (1SA044) receptacle. At this time, all Solenoid (Ohms)
LEDs should illuminate for a short period and then Shift Solenoid 1 20-30
turn off. This is the tester internal circuit check.
Shift Solenoid 2 20-30
6. Position Bench / Drive switch to BENCH mode.
(Continued)


ALL RIGHTS RESERVED
Dynamic Testing - Engine Running

Transmission
Application Dynamic testing is the final step in the transmission
E40D tester usage. It allows the transmission to be proven
Solenoid out electronically and hydraulically.
Resistance
Solenoid (Ohme) Transmission Solenoid Cycling and Drive Test
Torque Converter Solenoid 20-30 Preliminary Set-Up
Coast Clutch Solenoid 20-30 1. Set Bench / Drive switch to DRIVE mode.
Electronic Pressure Control 4.0-6.5 2. Set rotate gear select switch to GEAR SELECT
•• 1" position.
Transmission Fluid Temperature Sensor
3. Place vehicle in PARK.
• Set ohmmeter to 1000 ohm (k) scale. 4. Start engine.
• Connect ohmmeter positive lead to (+ ) transmission
oil temperature sensor jack. EPC Solenoid
• Connect ohmmeter negative lead to (-) transmission CAUTION: Do not attempt to hold the electronic
oil temperature sensor jack. pressure control switch depressed (minimum line
pressure) and stall the transmission (holding the
• Record resistance. Resistance will vary with vehicle with the brake while depressing the
temperat~re. throttle with the transmission In gear),
• Refer to the following chart. transmission damage will result.
If out of specification, refer to Pinpoint Test B in this 1. Observe line pressure. Record value. Line
section. pressure should go to maximum. If not, refer to
the Diagnosis by Symptom charts for diagnostic
tips or Pinpoint Test E concerning electronic
Temperature Resletance pressure control solenoid.
°c Of (Ohms)
2. Depress electronic pressure control switch. Line
(-)19-(-)1 (-)3-31 967K-248K pressure should drop to a minimum value. Record
(-)40-(-)20 (-)40-(-)4 248K-100K value. If not, refer to the Diagnosis by Symptom
charts or Pinpoint Test E for the electronic
0-20 32-68 100K-37K
pressure control solenoid.
21-40 69-104 37K-16K
Engagements
41-70 105-158 16K-5K
71-90 159-194 5K-2.7K
1. Verify that MODE switch is in DRIVE mode.
91-110 195-230 2.7K-1.5K 2. Turn GEAR SELECT dial to 1.
110-130 231-266 1.5K-0.8K 3. Start engine.
131-150 267-302 0.8K-0.54K 4. Shift vehicle from PARK to REVERSE.
Solenoid Voltage Test • Did vehicle shift into REVERSE?

NOTE: LED will turn GREEN when solenoid activates • Was engagement firm?
and turn OFF when deactivated. LED will turn RED if 5. Depress EPC switch. Line pressure should drop
an activated solenoid / harness is shorted to B+. LED to idle pressure.
will remain OFF if an activated solenoid / harness is While holding EPC switch down, shift vehicle from
shorted to ground or on continuity. PARK to REVERSE.
1. Set tester Bench / Drive switch to BENCH mode.
• Did vehicle shift into REVERSE?
2. Set voltmeter to 20 volt DC range.
• Was engagement smooth?
3. Connect voltmeter positive lead to the
appropriate solenoid vehicle power (VPWR). • Shift vehicle from REVERSE to PARK.
Connect voltmeter negative lead to the • Release EPC switch. Line pressure should rise
appropriate solenoid. to MAX pressure.
4. Using a Digital Volt-Ohmmeter (DVOM), check for 6. Shift vehicle from PARK to DRIVE.
voltage across each solenoid by activating the
solenoid switches. Depress the appropriate • Did vehicle shift into DRIVE?
switch. The LED should illuminate, the voltage • Was engagement firm?
should change and an audible click may be heard.
If LED does not illuminate, a short to ground 7. Shift vehicle from DRIVE to PARK.
condition exists. 8. Depress EPC switch. Pressure should drop to
5. Observe and record values. idle pressure.

ALL RIGHTS RESERVED
9. Depress EPC switch. Line pressure should drop Torque Converter Engagement
to idle pressure. While holding EPC switch down, NOTE: This test should be performed on the road. If
shift vehicle from PARK to DRIVE. performed on a hoist, feeling the torque converter
• Did the vehicle shift from PARK to DRIVE? clutch engage may not be possible.
• Was the engagement smooth? 1. CAUTION: Do not depress torque converter
clutch solenoid switch with transmission In
10. Release EPC Switch. gear and the vehicle at a stop. Damage to
Upshlft/Downshift torque converter clutch may result.
NOTE: Upshifts and downshifts will be firm during this Accelerate and shift vehicle up into third gear.
procedure. Pressure gauges may be removed. These Hold speed steady and depress the torque
tests should be performed on the road. If performed on converter clutch solenoid switch.
the hoist, feel at all shifts when they are engaged may • Does the torque converter engage?
not be possible.
• Does the engine rpm drop?
LEDs will turn GREEN when solenoids are activated
and turn OFF when deactivated. Refer to the • Did torque converter clutch solenoid activate?
appropriate overlay for the proper status shift 2. Holding speed steady, release switch.
sequence of the shift solenoids during upshifts and
downshifts. • Does torque converter clutch disengage?
1. Move gearshift selector lever into OVERDRIVE • Does RPM rise?
and accelerate to 24 km 1h (15 mph), select • Does TCC solenoid deactivate?
second gear by rotating gear selector to second.
3. Does the transmission pass these tests? If not
• Did vehicle upshift to second gear? refer to Diagnosis by Symptom section in this
manual.
• Did appropriate shift solenoids
activate 1deactivate? Coast Clutch Engagement
2. Accelerate to 40 km/h (25 mph) and select third NOTE: This test should be performed on the road. If
gear. performed on the hoist the technician may not feel the
coast clutch engage.
• Did vehicle upshift to third gear?
1. Accelerate and shift vehicle up into third gear.
• Did appropriate shift solenoids Depress the coast clutch solenoid switch and
activate 1deactivate? immediately back off the throttle.
3. Accelerate to 56-72 km/h (35/45 mph) and
select fourth gear. • Did the coast clutch engage? Did engine
braking occur?
• Did vehicle upshift to fourth gear? • Did the coast clutch solenoid activate?
• Did appropriate shift solenoids 2. Release the CCS switch.
activate 1deactivate?
4. Reverse the order to downshift. • Does the CCS solenoid deactivate?
• Does the coast clutch disengage?
• Does vehicle downshift from fourth to third,
third to second, and second to first? 3. Does the transmission pass these tests? If not
.refer to Diagnosis By Symptom section in this
• Did appropriate shift solenoids manual.
activate 1deactivate?
5. Does the transmission pass these tests? If not Transmission Tester Removal and Clearing
refer to Diagnosis by Symptom section in this DTCs
manual. 1. CAUTION: Do not attempt to pry off
connectors with a screwdriver. This will
damage the connector and could result In a
transmission concern. .
Disconnect transmission tester from transmission
connector.
2. Reinstall vehicle wiring harnesses. Verify
connection by pulling up on the harness.
3. Reinstall all transmission heat shields that were
previously removed.
4. Disconnect transmission tester power lead from
vehicle.
ALL RIGHTS RESERVED
5. Erase all DTCs using the procedures in the TR Tester Instructions

Powertrain Control/Emissions Diagnosis The Rotunda Transmission Tester 007-00085C allows
6
Manual. a technician to operate the electrical portion of the
6. Rerun EEC-IV On-Board Diagnostics to receive a transmission independent of the vehicle electronics.
pass code (11 or 111). This allows the technician to determine transmission
7. Verify customer concern has been eliminated. concerns.
Preliminary Testing and Diagnosis
Before any diagnostic testing is done on a vehicle
some preliminary checks must be performed, as
Transmission Range (TR) Sensor Testing - outlined below. Be sure to write down your findings,
Enhancement especially any DTCs found, for future reference.
The Rotunda Transmission Tester (007-Q085C or • Check transmission fluid level and condition.
equivalent) allows a technician to operate the
electrical portion of the manual lever position sensor. • Check for add-on items (phones, computers, CB
Usage of the Transmission Range (TR) Sensor Cable radio etc).
("MLPS" Manual Lever Position Sensor Cable) • Visually inspect wiring harness and connectors.
007-00086 or equivalent is divided into five steps:
• Check for vehicle modifications.
1. Preliminary diagnosis and testing.
• Verify that the shift linkage is properly adjusted in
2. Installing the Transmission Tester. OVERDRIVE.
3. Testing the Transmission Range (TR) sensor. • Verify that Transmission Range (TR) sensor is
4. Testing the Park/Neutral and Backup circuits. properly adjusted in NEUTRAL.
5. Removing the Transmission Tester (007-Q085C) • Verify customer concern; upshift, downshift,
and clearing Diagnostic Trouble Codes (DTCs). coasting, engagement, noise vibration.
• Vehicle must be at a normal operating temperature.
Transmission Range (TR) Sensor Tester • Perform vehicle On-Board Diagnostics.
• Record all DTCs.
TRANSMISSION TESTER • Service all non-transmission DTCs.
PARK/NEUTRAL
6 6
BACKUP LAMPS
6/1TRlMLP SENSORSI
ADDITIONAL
Transmission Tester Installation (Set-Up
Procedure)
Installing the Transmission Tester (007-0085C) at the
~~~~RE~~~TRAL 0
LED RED IN LED RED IN
PARK OR
NEUTRAL
0
STATUS
REVERSE
ONLY
0
STATUS
Transmission Range (TR) sensor allows the separation
ONLY IAXODE1'400 STATUS
IAx4s
IAX4N
AODE
E40D 95 of the vehicle electronics from the TR Sensor
HOLD TO TEST 0 HOLD TO TESTD
SWITCH TEST
D4E 4R7ow'D
4R44E
4RSSE
HOLD TO TEST
electronics.
During tester usage additional DTCs may be set.
Therefore, it is important that all codes are erased
FOR EACH SWITCH TEST. after service has been made. To verify elimination of
..
CD PRESS AND HOLD EACH SWITCH BUTTON WHILE
SHIFTING GEAR SELECTOR TO ALL GEAR POSITIONS . all DTCs, rerun On-Board Diagnostic.
LED FOR THE ACTIVE TEST SHOULD LIGHT RED ONLY
FOR THE INDICATED GEAR POSITION.
IF LED FAILS TO LIGHT FOR THAT GEAR POSITION OR
The following manuals should be available to assist in
IF IT LIGHTS FOR A DIFFERENT GEAR POSITION: diagnosis of electronically controlled transmissions:
• VERIFY MLP ALIGNMENT PER SHOP MANUAL. AND
• RETEST 7
• Powertrain Control/Emissions Diagnosis Manual.
SENSOR TEST
·~~~D CD
• Transmission Tester Manual (provided with tester).
a
CONNECT OHMMETER TO TRlMLP AND SIG RTN JACKS.
ev RECORD RESISTANCES IN EACH GEAR POSITION WHILE
0 BEFORE
SHIFTING GEAR SELECTOR TO ALL POSITIONS.
@ REFER TO TABLE.
@ IF VALUES ARE OUT OF RANGE. REFER TO SHOP MANUAL.
1. CAUTION: Do not attempt to pry off
connectors with a screwdriver. This will
damage the connector and could result in a
o ATTACHING
OVERLAY
SET SWITCH
IN DOWN
POSITION.
TAiMLP SENSOR TEST
0
• uNs~6 transmission concern.
CAUTION: Route all cables away from HEAT
SOURCES.
TR/MLP
-TRANSMISSION RANGE
SELECTOR POSITION MIN
RESISTANCE
MAX
Disconnect vehicle harness at transmission
PARK 3770 4607 manual lever position sensor connector.
REVERSE 1304 1593
0
TR/MLP
0
SIG RTN
NEUTRAL
OVERDRIVE·
SECOND/DRIVE t
660
361
150
807
442
232
FIRST 78 95
t REFER TO SHOP MANUAL
D14297-A

ALL RIGHTS RESERVED
2. NOTE: For in-vehicle testing use the transmission

Resistance (Ohme)
tester extension cable. Use cable A with the
E40D automatic transmission. Tranemlsslon
Gear Selector
Set Bench / Drive switch to DRIVE mode. Install Lever Poeltlon Minimum Maximum
Transmission Range (TR) sensor overlay onto
OVERDRIVE 361 442
tester. Connect interface cable to transmission
tester and then to the TR Sensor connector. MANUAL SECOND 190 232
Refer to chart for the proper cable/ application. MANUAL 1 78 95
3. Turn test select dial to the TR SENSOR TEST
position. Voltage Test - Park/Neutral, Backup Lamp and
Optional Circuit
4. Plug transmission tester power supply plug into
cigar lighter (1SA044). 1. Tester Selector Switch to the TR SENSOR TEST
position.
At this time, all LEOs should illuminate for a short
period and then turn off. This is the tester internal 2. Press and HOLD each button while moving the
circuit check. transmission range selector lever through EACH
gear position.
Testing TR Sensor
3. Monitor each LED.
Static testing procedures allow for shop testing of the
transmission in the vehicle or on the bench. 4. NOTE: LED will turn RED when the circuit closes
Completion of these tests prove out the Transmission and turn OFF when the circuit is open.
Range (TR) sensor electronically. The status LED should indicate RED only in the
CAUTION: For resistance checks, be sure that indicated position. Refer to overlay.
the tester selector switch Is set to the TR 5. If the LED does NOT indicate RED in the desired
SENSOR TEST position or damage to the position, or indicates RED in another position,
ohmmeter may result. first verify Transmission Range (TR) sensor
alignment and then retest. If the sensor fails,
Resistance/Continuity Tests
replace.
1. Using a digital volt-ohmmeter and the
Transmission Tester (007-Q08SC) and Transmission Tester Removal and Clearing DTCs
Transmission Range (TR) Sensor Cable ("MLPS" 1. CAUTION: Do not attempt to pry off
Manual Lever Position Sensor Cable) 007-00086 connectors with a screwdriver. This will
perform Pinpoint Test 0 based on the DTCs that damage the connector and could result In a
were displayed. transmission concern.
2. Perform services as indicated by the pinpoint Disconnect transmission tester from the
tests. Always retest and road test vehicle after Transmission Range (TR) sensor connector.
any service. 2. Reinstall vehicle wiring harness. Verify
TR Sensor Resistance Tests connection by pulling up on the harness.
1. Set ohmmeter to 1000 ohm range. 3. Disconnect transmission tester power lead from
vehicle.
2. Connect the positive lead of the ohmmeter to the
TRjack. 4. Erase all OTCs using the procedures in the
Powertrain Control/Emission Diagnosis Manual. 8
3. Connect the negative lead of the ohmmeter to the
.(Unlatch center button of Super Star Tester II
SIGRTN jack.
while codes are being displayed on a KOEO
4. Move transmission gearshift selector lever into On-Board Diagnostics.)
each gear position.
5. Rerun On-Board Diagnostic Tests to receive a
5. Record resistance at each position. pass code (11 or 111).
6. Refer to the following chart for values. 6. Verify that the customer concern has been
If out of range refer to Pinpoint Test D. eliminated.
Resistance (Ohms)
Transmission Pinpoint Tests
Gear Selector
Lever Position Minimum Maximum Use the following pinpoint tests to diagnose
transmission electrical concern.
PARK 3770 4607
If DTCs are present while performing the On-Board
REVERSE 1304 1593
Diagnostic, refer to On-Board Diagnostic Trouble
NEUTRAL 660 807 Code Description Chart for the appropriate service
(Continued) procedure.

1995 F-150. F-250. F-350, Bronco. F-Super Duty Powertrain, Drivetrain July 1994
ALL RIGHTS RESERVED
NOTE: Prior to entering Pinpoint Tests, refer to any • Transmission Wiring Harness, shift solenoid 1, shift
Technical Service Bulletins and Oasis messages for solenoid 2, vehicle power (VPWR)
E400 transmission concerns. • Powertrain Control Module - 12A650 (gasoline) or
NOTE: Prior to entering Pinpoint Tests, the vehicle 12B565 (diesel).
harness must be checked for continuity and shorts; Refer to the following schematic and charts when
the powertrain control module (PCM)( 12A650) must performing the Pinpoint Test Steps.
be checked for any concerns. Refer to the Powertrain
Control/Emissions Diagnosis Manual for proper
procedures. SEE CHART FOR TEST PINS
NOTE: If any non-transmission OTCs appear, service

TEST PIN o - O I Y - SS1
those codes first. They could affect the electrical
operation of the transmission. Record and erase TRANSMISSION
VEHICLE
codes from continuous memory after service has been HARNESS
performed. After servicing any OTCs in the Quick Test, CONNECTOR
the Quick Test should be repeated. TEST PIN Q-DG/R - SS2 ....-.--..1 1I~~_a.J
NOTE: Check powertrain control module wiring
harness for proper connections, bent or broken pins,
corrosion, loose wires, proper routing, proper seals
and their condition. Check the powertrain control TEST PIN 0- R - - . - - ~PWR
module sensors and actuators for physical damage. ~FROMEEC POWER RELAY
Pinpoint Test A - Shift Solenoids
Diagnostic Trouble Codes: P0781 /617, TEST PINS LOCATED ON BREAKOUT BOX.
P0782/618, P0783/619 Shift Errors, ALL HARNESS CONNECTORS VIEWED INTO MATING SURFACE. 012537-8
P0750/621, P0755/622 Solenoid Circuit
Failures
This Pinpoint Test is designed to diagnose the shift 4.9L,
PCMSlgnal S.8L-Callf 7.3LDI
solenoid electrical system only. To prevent Solenoid Output Pin S.OL Diesel
replacement of good components, note that the
following areas may be at fault: SS1 52 51 27
SS2 19 52 1
• Electrical- Battery, input sensors, wiring
harnesses VPWR 37,57 37,57 71,97
• Transmission - Internal transmission components, SS 1 = Shift Solenoid No. 1

linkage SS2 = Shift Solenoid No.2
This Pinpoint Test is designed to diagnose the
following components:
Solenoid Operation Chart

The following solenoid application chart shows normal
solenoid operation for given operating modes.
SOLENOID OPERATION CHART
Park First ON OFF OFF OFF
Reverse First ON OFF OFF OFF
Neutral First ON OFF OFF OFF
~ First ON OFF • •
~ Second ON ON a •
~ Third OFF ON • •
~
a
Fourth OFF OFF OFF
(Continued)
ALL RIGHTS RESERVED
07-01A·77 Transmission, Automatic, E40D 07-01A-77
SOLENOID OPERATION CHART (Cont'd)

f) First Through Third Gear Only, Shift Solenoid 1, Shift Solenoid 2, and Torque Converter Clutch, Same as
Cancel Overdrive, Coast Clutch Solenoid Always On•
Manual 2 Second OFF OFF • ON
Manual 1 Second OFF OFF OFF ON
Manual 1 First ON OFF OFF ON
a Powertrain control module controlled.
Shift Solenoid Failure Mode Charts Shift Control Solenoid· Failure "Always OFF"
Shift Control Solenoid Failure "Always ON" Failed OFF due to powertrain control module and / or
vehicle wiring concerns; solenoid electrically or
Failed ON due to powertrain control module and / or hydraulically stuck OFF.
vehicle wiring concerns; solenoid electrically or
hydraulically stuck ON.
Shltt Solenoid 1 ALWAYS OFF
Shltt Solenoid 1 ALWAYS ON Powertraln
Control Module Position Position Position
Powertraln Gear Selected: Selected: Selected:
Control Module Position Position Position Commanded Overdrive 2 1
Gear Selected: Selected: Selected:
Commanded Overdrive 2 1 Actual Gear Obtained
Actual Gear Obtained 1 4 2 1

2 3 2 2
1 1 2 1
3 3 2 2
2 2 2 1
4 4 2 2
3 2 2 1
4 1 2 1
Shltt Solenoid 2 ALWAYS OFF
Shltt Solenoid 2 ALWAYS ON Powertraln
Control Module Position Position Position
Powertraln Gear Selected: Selected: Selected:
Control Module Position Position Position Commanded Overdrive 2 1
Gear Selected: Selected: Selected:
Commanded Overdrive 2 1 Actual Gear Obtained
Actual Gear Obtained 1 1 2 1

2 1 2 1
1 2 1 1
3 4 2 2
2 2 2 1
4 4 2 2
3 3 2 2
4 3 2 2
PINPOINT TEST A: SHIFT SOLENOIDS

A1 I E40D ELECTRONIC DIAGNOSTICS
~ REMAIN in Output State
• Check to make sure the transmission harness
connector is fully seated, terminals are fully
Yes
DTM. GO to A2.
engaged in connector and in good condition before No ~ DEPRESS throttle and
proceeding. release. If vehicle did not
• Enter Output State Diagnostic Test Mode (DTM).
Refer to Special Test Modes in this section.
enter Output State DTM,
REFER to Powertrain
•• Connect Star tester.
Perform KOEO test until continuous memory DTC
Control/Emission
Diagnosis Manual. 9
have been displayed.
• Depress throttle to Wide Open Throttle (WOT) and
release.
• Doe8 vehicle enter Output State DTM?


ALL RIGHTS RESERVED
DIAGNOSIS AND rESTING (Continued)
PINPOINT TEST A: SHIFT SOLENOIDS (Continued)

A2 I CHECK ELECTRICAL SIGNAL OPERATION
CAUTION: Remove heat shield from transmission Yes ~ GOtoA5.
before removing connector. Remove Solenoid Body No ~ GOtoA3.
connector by pushing on center tab and pulling on
wiring harness. Do not attempt to pry tab with a
screwdriver. Reinstall heat shield after service.
NOTE: Refer to the schematic and charts preceding

this Pinpoint Test.
•• Disconnect transmission connector.

Using a mirror, inspect both ends of connector for
damaged or pushed out pins, corrosion, loose wires,
and missing or damaged seals.
• Connect a volt-ohmmeter positive lead to vehicle
power (VPWR) circuit and negative test lead to
solenoid circuit of transmission vehicle harness
connector.
•• Place volt-ohmmeter on 20 volt scale.
While observing volt-ohmmeter, depress and
release throttle to cycle solenoid output On and Off.
• Does the suspected solenoid output voltage
change at least.0.5V?
A3 ICHECK CONTINUITY OF SOLENOID SIGNAL AND
VEHICLE POWER HARNESS CIRCUITS
•• Turn ignition switch off.
Make sure harness transmission connector is
Yes ~ GOtoA4.
No ~ SERVICE open circuit(s).
disconnected. REMOVE Breakout Box.
• Disconnect powertrain control module. Inspect for
damaged or pushed out pins, corrosion, or loose
RECONNECT all
components. REPEAT
wires. Quick Test.
• Install Rotunda EEC-IV 60-Pin Breakout Box
007-00033, leave powertrain control module
disconnected.
this Pinpoint Test.
• Measure resistance between powertrain control

module signal test pin 52 or 19 (51, 52, - 4.9l
Calif, 5.8l Calif, 5.0l) (1,27-Diesel) at Breakout Box
and signal pin at transmission harness connector.
module signal test pins 37 and 57, 71, 97 (Diesel) at
Breakout Box and signal pin at transmission harness
connector.
I•
Is each resistance less than 5.0 ohms?
A4 CHECK SOLENOID HARNESS FOR SHORTS TO
POWER AND GROUND
• Make sure Rotunda EEC-IV 60-Pin Breakout Box
007-00033 is installed and powertrain control
Yes ~ GOtoA5.
No ~ SERVICE short circuit.
module is disconnected. REMOVE Breakout Box.
• Ensure transmission harness connector is
disconnected.
RECONNECT all
components. REPEAT
NOTE: Refer to the schematic and charts preceding Quick Test.
this Pinpoint Test.

module signal output pin and test pin 37/57 (71, 97
Diesel) at Breakout Box.
• Measure resistance between test pins 40/60 77,
103 and 46, 91 (Diesel) at Breakout Box and
chassis ground.
• Is each resistance greater than 10,000 ohms?

ALL RIGHTS RESERVED

AS SOLENOID FUNCTIONAL TEST
• Ensure that the vehicle harness is disconnected at Yes ~ GOtoA6.
the transmission connector. No ~ GOtoA7.
• Install Transmission Tester 007-00a5C.
• Using tests outlined under Tester Instructions,
perform the Solenoid Voltage Test.
NOTE: LED will turn "GREEN" when solenoid
activates and turn "OFF" when deactivated. LED
will turn "RED" if activated solenoid is shorted to
B+. LED will remain "OFF" if an activated solenoid
is shorted to ground or no continuity.
• Do solenoids activate? (LED GREEN)
A6 TRANSMISSION DRIVE TEST
• Perform Trans.mission Solenoid Cycling Test Yes ~ ERASE all codes and
Procedures as outlined under Transmission Tester PERFORM Drive Cycle
Instructions in this section. Test in this section.
• Does vehicle upshift when commanded by the REPEAT Quick Test.
tester? No ~ GOtoA7.
A7 CHECK RESISTANCE OF SOLENOID
• Bench / Drive switch in BENCH mode. Yes ~ GOtoA8.
• Rotate gear selector switch to OHMS CHECK No ~ REPLACE solenoid body
position. assembly. RECORD and
• Connect a volt-ohmmeter negative lead to the shift ERASE codes. REPEAT
solenoid 1 jack and positive lead to vehicle power Quick Test.
jack on tester. This is to test shift solenoid 1.
• Record resistance.
• Connect a volt-ohmmeter negative lead to the shift
solenoid 2 jack and positive lead to the vehicle
power jack on tester. This is to test shift solenoid 2.
• Are shift solenoids resistance between 20 and
30 ohms?
CONNECT VOM BETWEEN

THESE JACKS FOR EACH SOLENOID
TATUS~--2.....---a..-~
-1
o ~~L.2ff-JWff..J
VPWR SS-2 LO wEJl eJEN " ClR~EN .do

L GEAR SELECT ..-.J
D12538-B

ALL RIGHTS RESERVED

AS CHECK SOLENOID FOR SHORT TO GROUND
• Check for continuity between BAT(-) (engine Yes ~ REPLACE solenoid body
ground) and appropriate jack with a digital assembly. RECORD and
volt-ohmmeter or other low current tester (less than ERASE codes. REPEAT
200 milliamps). Quick Test.
• Connection should show infinite resistance (no No ~ GO to Diagnosis by
continuity).
Symptom Section.
SHIFT SOLENOIDS
vp
CONNECT VOM BETWEEN BAT

(-) JACK AND EACH OF THE
SOLENOID JACKS
D12539-B
TO 12536C
Pinpoint Test B - Transmission Fluid This Pinpoint Test is designed to diagnose the
Temperature (TFT) Sensor following components:
Diagnosis Trouble Codes: P1711 /636 Out of • Transmission Wiring Harness Transmission Fluid
Self-Test Range, P0713/637, P0712/638, Temperature Sensor (TFT Sensor) Signal Return
Transmission Fluid Temperature Sensor Circuit (SIGRTN).
Open/Grounded P1783/657 Transmission • Powertrain Control Module 12A650 (gasoline) or
Overtemp Indicated 12B565 (diesel).
Transmission Fluid Temperature Sensor electrical
system ONLY. To prevent replacement of good
components, note that the following areas may be at
fault: .
• Engine - Cooling
• Electrical- Battery, wiring harnesses
• Transmission - Internal transmission components,
cooling, fluid

ALL RIGHTS RESERVED
Refer to the following schematic and charts when

performing the Pinpoint Test Steps.
4.9L CALIF
COMPONENT POWERTRAIN CONTROL MODULE 5.0L
SIGNAL OUTPUT PIN 5.8L CALIF
TFT 37 (DIESEL)
49
42 (GAS)
SRTN 91 (DIESEL) 46
46
TFT =TRANSMISSION FLUID TEMPERATURE
SRTN = SENSOR SIGNAL RETURN
TEST PIN 0- O/BK- TFT - _ - . l J U b I......~1
TRANSMISSION
VEHICLE
TEST PIN 46 0- GY/R - SRTN HARNESS
CONNECTOR
SEE CHART FOR TEST PINS

ALL HARNESS CONNECTORS VIEWED INTO MATING SURFACE.
012541-8
PINPOINT TEST B: TFT SENSOR

B1 I E40D ELECTRONIC DIAGNOSIS
• Check to make sure transmission harness
Yes
No
~ GOtoB2.
~ PERFORM checks.
engaged in connector and in good condition before ERASE codes. REPEAT
proceeding. Quick Test.
• Have items been checked?
B2 I CHECK ELECTRICAL SIGNAL OPERATION
~ GOto B3.
••
Turn ignition switch off. Yes
Disconnect transmission connector. No ~ REFER to Powertrain
CAUTION: Remove heat shield from transmission Control/Emission
before removing connector. Remove Solenoid Diagnosis Manual 10 for
Body connector by pushing on center tab and diagnosis of no reference
pulling on wiring harness. D.o not attempt to pry voltage.
tab with a screwdriver. Reinstall heat shield after
service.
• Using a mirror, inspect both ends of connector for

damaged or pushed out pins, corrosion, loose
wires, and missing or damaged seals.
this Pinpoint Test.
• Connect a volt-ohmmeter positive test lead to

transmission fluid temperature sensor circuit and
negative test lead to Signal Return (SIG RTN) circuit
of transmission harness connector.
••
Place volt-ohmmeter on 20 volt scale.
Turn key on, engine off.
• Is voltage between 4.75 and 5.25 volts?


ALL RIGHTS RESERVED
PINPOINT TEST B: TFT SENSOR (Continued)

B3 CHECK CONTINUITY OF TRANSMISSION FLUID
TEMPERATURE SENSOR AND SIGNAL RETURN
CIRCUITS
• Turn ignition switch off. Yes ~ GO to B4.

• Make sure that the vehicle harness is disconnected
at the transmission connector.
REMOVE Breakout Box.
damaged or pushed out pins, corrosion or loose
RECONNECT all
components. ERASE
wires. codes. REPEAT Quick
007-00033 or equivalent. Leave powertrain control
Test.
module disconnected.
this Pinpoint Test.

module signal test pin 42 (49 5.0L, 4.9L Calif, 5.8
Calif), (37-diesel only) at Breakout Box and signal
pin at transmission harness connector.
module signal test pin 46 or 91 (Diesel) at Breakout
Box and signal pin at transmission harness
connector.
• Are both resistances less than 5.0 ohms?
B4 CHECK TRANSMISSION FLUID TEMPERATURE
SENSOR CIRCUIT FOR SHORT TO VEHICLE POWER
AND GROUND
• Turn ignition switch off. Yes ~ GOtoB5.

• Make sure Transmission harness connector is
disconnected.
RECONNECT all
components. ERASE
wires. codes. REPEAT Quick
007-00033 or equivalent. Lea\le powertrain control
Test.
this Pinpoint Test.
• Measure resistance between transmission fluid

temperature test pin and pins 37 /57 or 71, 97
(Diesel) at Breakout Box.

ALL RIGHTS RESERVED

B5 ITEMPERATURESENSOR/HARNESS
CHECK RESISTANCE OF TRANSMISSION FLUID

Yes ~ GOtoB6.
No ~ REPLACE solenoid
• Install Transmission Tester (007 -0085C) to
transmission connector.
assembly. RECORD and
ERASE codes. REPEAT
••
Set Bench I Drive switch to BENCH mode. Quick Test.
Rotate gear selector switch to OHMS/DIODE
CHECK position.
• Connect a volt-ohmmeter negative lead to -TFT jack
and positive lead to +TFT jack on tester.
• Perform Tests 1 and 2 (continued on the following
page).
NOTE: While performing Tests 1 and 2 observe
resistances.
- Code poi 13 I 637 is set if resistance value
exceeds 869K ohms (open circuit).
- Code P0712 1638 is set if resistance value falls
below 597 ohms (short circuit).
CONNECTVOM
ACROSSTHESEJACKS~
~~ + -
D12542·B
TEST NO. 1
••
Record resistance .
Resistance should be approximately in the following
ranges:
TRANSMISSION FLUID TEMPERATURES
Resistance
°C of (Ohms)
(-) 19-(-) 1 (-)3-31 967K-248K
(-)40-(-)20 (-)40-(-)4 248K-100K
0-20 32-68 100K-37K
21-40 69-104 37K-16K
41-70 105-158 16K-5K
71-90 159-194 5K-2.7K
91-110 195-230 2.7K-1.5K
111-130 231-266 1.5K-0.8K
131-150 267-302 0.8K-0.54K
TEST NO. 2
• Check for intermittent short or open .
- If resistance was between 0.8K and 100K
ohms, perform following test:
(a) If transmission is cold, start and run engine
until transmission reaches its normal
operating temperature. If transmission is
warm, allow to cool.
(b) Check transmission fluid temperature
sensor resistance again.
• Compare resistance with initial resistance .
Resistance should decrease if transmission was
warmed and should increase if transmission was
allowed to cool. If correct change in resistance
1995 F-150. F-250. F-350, Bronco. F-Super Duty Powertrain, Drivetrain July 1994

ALL RIGHTS RESERVED

TEST STEP . RESULT ~ ACTION TO TAKE
occurs, repea UIC es.
• Is resistance within range?
B6 CHECK TRANSMISSION FLUID TEMPERATURE
SENSOR FOR SHORT TO GROUND
• Check for continuity between engine ground (BAT-) Yes ~ REPLACE solenoid
and appropriate jack (-TFT or +TFT) using a assembly. REPEAT Quick
volt-ohmmeter or other low current tester (less than Test.
200 milliamps).
No ~ REPEAT Quick Test. If
- Connection should show infinite resistance (no codes are present and
continuity).
overtemp condition
• Is there continuity? existed, CHECK fluid
condition. CHECK
CONNECT VOM BETWEEN overheat condition in the
BAT (-) AND EACH JACK Diagnosis by Symptom
Routine. SERVICE as
required. REPEAT Quick
Test.
+
o o
B AT + BAT -
PIut No. 3122-881
012543-8
T012540C
Pinpoint Test C - Torque Converter Clutch

(TCC) Solenoid POWERTRAIN CONTROL MODULE
SOLENOID
SIGNAL OUTPUT PIN
Diagnosis Trouble Codes: P0743/629 Torque
53
Converter Clutch Solenoid Circuit Failure TCC
28 (DIESEL)
This Pinpoint Test is designed to diagnose the Torque TCC = TORQUE CONVERTER CLUTCH
Converter Clutch Solenoid electrical system ONLY. To VPWR = VEHICLE POWER
EEC = ELECTRONIC ENGINE CONTROL
prevent replacement of good components, note that
the following areas may be at fault:
TEST PIN 530- PIW - TCC
• Electrical- Battery, input sensors, wiring 28 (DIESEL)
I f I -............... 11I TRANSMISSION
harnesses, brake switch 11--tI)CC)(1I1I VEHICLE
HARNESS
• Transmission - Internal transmission components, CONNECTOR
linkage, cooling
TEST PINo- R
37/57
~PWR
71, 97 (DIESEL)
FROM EEC POWER RELAY
• Transmission Wiring Harness, Torque Converter
Clutch Solenoid, Vehicle Power (VPWR)
• Powertrain Control Module 12A650 (gasoline) or TEST PINS LOCATED ON BREAKOUT BOX.
128565 (diesel).
Refer to the following schematic and charts when D12545-8
performing the Pinpoint Test Steps.

ALL RIGHTS RESERVED
PINPOINT TEST C: TCC SOLENOID

C1 I E40D ELECTRONIC DIAGNOSTICS
Yes ~ REMAIN in Output State
DTM. GO to C2.
engaged in connector and in good condition before No ~ DEPRESS throttle and
proceeding. RELEASE. If vehicle did
not enter Output State
DTM,REFERto
• Connect STAR Tester or equivalent. Powertrain
• Perform KOEO TEST until continuous memory DTC
Control/Emission
Diagnosis Manual. 11
• Depress throttle to wide open throttle and release.
• Does vehicle enter Output State (DTM)?
C2 I CHECK ELECTRICAL SIGNAL OPERATION
CAUTION: Remove heat shield from transmission Yes ~ GOtoC5.
before removing connector. Remove Solenoid Body No ~ GOtoC3.
• Disconnect transmission connector.

this Pinpoint Test.
• Connect a volt-ohmmeter positive test lead to

VPWR circuit and negative test lead to solenoid
circuit of transmission vehicle harness connector.
• While
• releaseobserving volt-ohmmeter, depress and
throttle to cycle solenoid output On and Off.
• change
Does the suspected solenoid output voltage
at least O.5V?
C3 ICHECK CONTINUITY OF SOLENOID SIGNAL AND
V.EHICLE POWER HARNESS CIRCUITS
•• Make
Turn ignition switch off.
sure transmission harness connector is
Yes
No
~ GOtoC4.
~ SERVICE open circuit(s).
• damaged
Disconnect powertrain control module. Inspect for
or pushed out pins, corrosion, or loose
RECONNECT all
components. REPEAT
wires. Quick Test.
• Install Rotunda EEC-IV aO-Pin Breakout Box
007-00033. Leave powertrain control module
disconnected. ,-
this Pinpoint Test.

module signal test pin 53, 28 (Diesel) at Breakout
connector.
• Measure resistance between test pin 37/57 71, 97
(Diesel) at Breakout Box and VPWR pin at
transmission harness connector.
• Is each resistance less than 5.0 ohms?


ALL RIGHTS RESERVED
PINPOINT TEST C: TCC SOLENOID (Continued)

C4 ICHECK SOLENOID HARNESS FOR SHORTS TO
POWER AND GROUND

Yes ~ GOtoC5.
• Make sure transmission harness connector is
disconnected.
RECONNECT all
components. REPEAT
this Pinpoint Test.

module signal test pin 53, 28 (Diesel) and test pin
37/57 71, 97 (Diesel) at the Breakout Box.
• Measure resistance between test pin 40/60 77, 103
(Diesel) and 46, 91 (Diesel) at Breakout Box and
chassis ground.
C5 I SOLENOID FUNCTIONAL TEST
• Disconnect vehicle harness at transmission. Yes ~ GOtoC6.
• Install Rotunda Transmission Tester (007 -0085C). No ~ GOtoC7.
• Using tests outlined under Tester instructions,
perform the Solenoid Voltage Test.
NOTE: LED will turn "GREEN" when solenoid
activates and turn "OFF" when deactivated. LED
will turn "RE D" if activated solenoid is shorted to
B+. LED will remain "OFF" if an activated solenoid
is shorted to ground or no continuity.
• Do solenoids activate? (LED GREEN)?

C6 I TRANSMISSION DRIVE TEST
• Procedures
Perform Transmission Solenoid Cycling and Test
as outlined under Transmission Tester
Yes ~ ERASE all codes and
PERFORM Drive Cycle
Instruction in this section. Test in this section.
• Does Torque Converter Clutch activate when
commanded by tester?
REPEAT Quick Test.
No ~ GOtoC7.
• Does the engine rpm drop?
C7 I CHECK RESISTANCE OF SOLENOID
• Set Bench / Drive switch to BENCH mode. Yes ~ GOtoC8.
• Rotate gear select switch to OHMS CHECK
position.
No ~ REPLACE solenoid body
assembly.
• Connect 'a volt-ohmmeter negative lead to torque
converter clutch solenoid (TCC) jack and positive
lead to vehicle power (VPWR) jack on tester.
• Resistance should be between 20-30 ohms.
• Is resistance between 20-30 ohms?
TCC
l.() 0
CONNECTVOM~ VPWR STATUS
ACROSS THESE JACKS ACTIVATE
~.
TCC
D
D125-.&

ALL RIGHTS RESERVED
PINPOINT TEST C: TCC SOLENOID (Continued)

C8 CHECK SOLENOID FOR SHORT TO GROUND
• Check for continuity between engine ground (BAT-) Yes ~ REPLACE solenoid body
and appropriate jack with a volt-ohmmeter or other assembly.
low current tester (less than 200 milliamps). No ~ GO to Diagnosis by
• Connection 'should show infinite resistance (no Symptom Routine for
continuity). torque converter clutch
• Is there c9ntinuity? diagnosis.
CONNECT VOM BETWEEN
BAT(-) JACK AND EACH OF
THE SOLENOID JACKS
Tee
o
BAT-
D12547-B
TD12544C
Pinpoint Test D - Transmission Range (TR) • Engine - Starter, starter relay

Sensor • Electrical- Battery, ignition switch, wiring
Diagnostic Trouble Codes: 659, P1706 harnesses
Transmission Range (TR) Sensor Indicating PARK • Transmission - External transmission linkages
During Operation This Pinpoint Test is designed to diagnose the
P0707, 667 TR Sensor, Circuit Grounded or following components:
Shorted, 668, P0708 TR Sensor, Circuit OPEN
P0705/634 TR Sensor Error Detected • Transmission Wiring Harness, TR Sensor, Signal
654 TR Sensor Not in Park Return (SIG RTN)
Thts Pinpoint Test is designed to diagnose the TR • Powertrain control module (PC~)( 12A650).
Sensor electrical system ONLY. To prevent Refer to the following schematic and charts when
replacement of good components, note that the performing the Pinpoint Test Steps.
following areas may be at fault:

ALL RIGHTS RESERVED
Transmission Range (TR) Sensor
TERMINAL DESCRIPTIONS
57 Ground Circuit
199 TR Sensor Signal
359 Sensor Signal Return TEST PIN 46 TEST PIN 30
463 Neutral to Transfer Case 359 (GY/R) 199 (LBN)
33 Start Circuit TEST PIN 91 TEST PIN 64

(GY/R) DIESEL (LB/V) DIESEL
140 Backup Lamp
57 (BK) (GY/R) (LSN) 463 (RIW)
298 Fused Accy Feed
32 Start Circuit
33 140 298 33
(R/LS) (BKlPK) (P/O) (R/LB) D12549-8
COMPONENT TESTING PROCEDURE CHART

Connect
Self-
Powered
Test Lamp or
Ohmmeter
To Test to Terminals Move Switch to These Positions A Good Switch Will Indicate
Transmission Circuit 359 (GV /R) Park 3770-4607 Ohms / 4.41 Volts·
and 199 Reverse 1304-1593 Ohms/3.60 Volts·
(LB/V) Neutral 660-807 Ohms/2.93 Volts·
0/0 361-442 Ohms/2.09 Volts·
Second (2) 190-232 Ohms/ 1.37 Volts·
First (1) 78-95 Ohms /0.68 Volts·
Backup Lamp Circuit 298 (P/O) Park Greater than lOOK Ohms
and 140 Reverse Less than 5.0 Ohms
(BK/PK) Neutral Greater than lOOK Ohms
0/0 Greater than lOOK Ohms
Second (2) Greater than lOOK Ohms
First (1) Greater than lOOK Ohms
Starter Relay Circuit 33 (W/PK) Park Less than 5.0 Ohms
and 32 Reverse Greater than lOOK Ohms
(R/LB) Neutral Less than 5.0 Ohms
Neutral Sensing to Transfer Case 463 (R/W) Park Greater than lOOK Ohms
and 57 (BK) Reverse Greater than lOOK Ohms
Neutral Less than 5.0 Ohms
a Voltages may vary ± 10% due to sensor and VREF variations.
TD12564B

ALL RIGHTS RESERVED
07-0 1A-89 Transmission, Automatic, E40D 07-01A-89
Transmission Range (TR) Sensor Tester
TRANSMISSION TESTER
PARK/NEUTRAL
6 6 BACKUP LAMPS
6/1TRIMlP SENSORS)
ADDITIONAL
lEDBe.QIN lEDReQIN lED~IN: 0
PARK OR
NEUTRAL
0 REVERSE
ONLY
0
STATUS
~:~B!'Jj
STATUS AXODEr40D STATUS
ONLY AX4S AODE
AX4N E40D 95·
CD4E 4R7OW'D
4R44E
4RSSE
HOlD TO TEST D HOlD TO TESTD HOLD TO TEST
SWITCH TEST
FOR EACH SWITCH TEST.
eDPRESS AND HOlD EACH SWITCH BunON WHilE
SHIFTING GEAR SELECTOR TO ~l GEAR POSITIONS.
- LED FOR THE ACTIVE TEST SHOULD LIGHT REO ONLY

FOR THE INOfCATED GEAR POSITION.
- IF LED FAllS TO LIGHT FOR THAT GEAR POSITION OR

IF IT LIGHTS FOR A DIFFERENT GEAR POSITION:
- VERIFY MLP AlIGNMENT PER SHOP MANUAl. AND
-RETEST
NOT SENSOR TEST
a
• USED eD CONNECT OHMMETER TO ~LPAND SIG RTN JACKS.
Q) RECORD RESISTANCES IN EACH GEAR POSITION WHILE
SHIFTING GEAR SELECTOR TO ALL POSITIONS.
@ REFER TO TABLE.
D @ IF VALUES ARE OUT OF RANGE. REFER TO SHOP MANUAl.
BEFORE
ATIACHING
OVERLAY
TAIMlP SENSOR TEST
·u~6
DSETSWITCH
IN DOWN
POSITION. D
-TRANSMISSION RANGE RESISTA~
TRlMLP SELECTOR POSITION
PARK
MIN
3770
MAX
4607
REVERSE 1304 1593
0
TRlMLP
0
SIG RTN
NtUTRAL
OVERDRIVE·
SECOND/DRIVE t
660
361
150
807
442
232
FIRST 78 95
t REFER TO SHOP MANUAL
D14297-A
PINPOINT TEST 0: TR SENSOR

01 I E40D ELECTRONIC DIAGNOSTICS
NOTE: Code 67/634/654 may also be set by running Yes ~ REMOVE tool. GO to 02.
Quick Tests with the transmission not in PARK or with No ~ ADJUST sensor. REFER
the AI C On. Make sure Quick Tests are performed to Section 07-14A for
properly.
Transmission Range (TR)
• Check to make sure manual lever position sensor
harness connector is fully seated, terminals are fully
Sensor adjustment
procedure. After
engaged in connector and in good condition before adjustments, PLACE
proceeding. transmission gearshift
• Verify shift linkage adjustment in DRIVE. selector lever in PARK.
•• Turn ignition switch off.
Apply parking brake.
CLEAR DTCs and
REPEAT Quick Test.
•• Place transmission in NEUTRAL.
Verify that Transmission Range (TR) Sensor
Alignment Tool T92P-70010-AH (MLPS Alignment
Tool) fits in the appropriate slots.
• Is the Transmission Range (TR) Sensor properly
adjusted?

ALL RIGHTS RESERVED
PINPOINT TEST 0: TR SENSOR (Continued)

02 I CHECK ELECTRICAL SIGNAL OPERATION
••
Turn ignition switch off. Yes ~ GOto03.
Disconnect transmission connector. No ~ REFER to Powertrain
CAUTION: Do not pry on connector. Pull up on Control/Emissions
vehicle harness connector. Diagnosis Manual 12 for
diagnosis of no reference
• Using a mirror, inspect both ends of the connector
for damaged or pushed out pins, corrosion, loose
voltage.
wires and missing or damaged seals.

NOTE: Refer to the schematic and chart preceding
this pinpoint test.
• Connect a volt-ohmmeter positive test lead to TR

sensor circuit and negative test lead to Signal
Return circuit of transmission harness connector.
••
Turn key on, engine off (KOEO).
• Is voltage between 4.75 and 5.25 volts?
03 ICHECK CONTINUITY OF TRANSMISSION RANGE (TR)
SENSOR HARNESS CIRCUITS
• Turn ignition switch off. Yes ~ GOto 04.
CAUTION: Do not pry connector. Squeeze TABS No ~ SERVICE open circuit(s).
and pull up on vehicle harness. REMOVE Breakout Box.
RECONNECT all
• Disconnect TR sensor. components. ERASE
• Inspect for damaged or pushed out pins, corrosion,
or loose wires.
codes. REPEAT Quick
Test.
007-00033. Leave powertrain control module
disconnected.
• Disconnect powertrain control module.
- Inspect for damaged or pushed out pins,
corrosion, or loose wires.
NOTE: Refer to the schematics and charts
preceding this Pinpoint Test.
• Measure resistance between test pin 46 or 91

(Diesel) at Breakout Box and signal return circuit at
TR sensor harness connector.
(Diesel) at Breakout Box and TR sensor circuit at TR
sensor harness connector.
04 ICIRCUIT
CHECK TRANSMISSION RANGE (TA) SENSOR
FOR SHORTS TO POWER AND GROUND

Yes ~ GOto 05.
• Make sure TR sensor harness connector is
disconnected.
RECONNECT all
components. ERASE
NOTE: Refer to the schematics and charts codes. REPEAT Quick
preceding this Pinpoint Test. Test.

(Diesel) and test pins 37 / 57, 40/60, and 46 or
71 /97, 77 / 103, 91 (Diesel) at Breakout Box.
(Diesel) at Breakout Box and chassis ground.


ALL RIGHTS RESERVED
PINPOINT TEST 0: TR SENSOR (Continued)

05 ICHECK
SENSOR
OPERATION OF TRANSMISSION RANGE (TR)
• Disconnect TR sensor harness connector at

transmission.
Yes ~ Problem not in sensor or
circuits. If technician was
• Connect Transmission Tester (007 -0085C) with
Transmission Range (TR) Sensor Cable ("MLPS"
directed here from
Diagnosis by Symptom,
Manual Lever Position Sensor Cable) 007-00086 to RETURN to routine and
manual lever position sensor. CONTINUE.
• Using procedures provided with tester, verify sensor
functions in all positions.
If technician was directed
here by Diagnostic
- Check continuity and resistance in all positions. Trouble Code and
• Is the TR sensor OK? condition is not repaired,
GO to Powertrain
Transmission Resistance Resistance Control/Emissions
Gearshift Selector (Ohms) (Ohms) Voltage Diagnosis Manual 13 to
Lever Min. Max. Range DIAGNOSE intermittent
operation.
P 3770 4607 3.97-4.85
No ~ REPLACE TR sensor and
R 1304 1593 3.24-3.96 ADJUST. REFER to
N 660 807 2.55-3.11 Section 07-14A for
0 361 442 1.88-2.30
Sensor Adjustment.
2 190 232 1.23-1.51 RECORD and ERASE
0.61-0.75
codes, REPEAT Quick
1 78 95
Test.
TD12548C
Pinpoint Test E - Electronic Pressure Control This Pinpoint Test is designed to diagnose the
(EPC) Solenoid following components:
Diagnostic Trouble Codes: P1747 /624,625, • Transmission Wiring Harness, electronic pressure
P1746 Electronic Pressure Control Error control, electronic pressure control power.
Detected • Powertrain Control Module - 12A650 (gas) or
This Pinpoint Test is designed to diagnosis the 128565 (diesel).
electronic pressure control solenoid electrical system Refer to the following schematic and charts when
ONLY. To prevent replacement of good components, performing the Pinpoint Test Steps.
note that the following areas may be at fault:
• Engine - Performance
• Electrical- Battery, input sensors, wiring
harnesses
13 Can be purchased as a separate item


ALL RIGHTS RESERVED
Electronic Pressure Control Solenoid
Solenoid Powertrain Control Module

Signal Output Pin
EPC 38 TRANSMISSION
VEHICLE
HARNESS
EPC = ELECTRONIC PRESSURE CONTROL TEST PIN 81 (DIESEL)
CONNECTOR
TEST PIN 38 o - - L B I Y - - - E P C
Test Pins 35 and 37/57 - EPC PWR

Application Wire Color
SOLENOID
TEST PIN 37/57 O - - -..P
...O..
W...E-R.....- -.........- - - -
7.3L Diesel YIW
TEST PIN 71, 97 (DIESEL)
4.9L, 5.0L, 5.8L &7.5L Ror RIW

ALL HARNESS CONNECTORS VIEWED INTO MATING SURFACE. 012551-8
PINPOINT TEST E: EPC SOLENOID

E1 IE40D ELECTRONIC DIAGNOSTICS CHECK VEHICLE
POWER (VPWR) TO SOLENOID

Yes ~ GOtoE2.
No ~ SERVICE open in
engaged in connector and in good condition before
harness. RECONNECT all
proceeding.
components. ERASE
• Turn ignition Off.
codes. REPEAT Quick
CAUTION: Remove heat shield from transmission Test.
before removing connector. Remove solenoid
Body connector by pushing on center tab and
pulling on wiring harness. Do not attempt to pry
tab with a screwdriver. Reinstall heat shield after
service.

NOTE: Refer to the schematic and charts
preceeding this Pinpoint Test.
••
Turn key On, engine Off.
Measure the voltage between electronic pressure
control power circuit at transmission harness
connector, and chassis / battery ground.
• Is voltage greater than 10.5 volts?
E2 ICHECK CONTINUITY OF SOLENOID SIGNAL AND
VEHICLE POWER (VPWR) HARNESS CIRCUIT
••
Turn ignition switch off. Yes ~ GOtoE3.
Disconnect powertrain control module. Inspect for No ~ SERVICE open circuit.
damaged or pushed out pins, corrosion, or loose
wires.
RECONNECT all
007-00033 or equivalent. Leave powertrain control
components. ERASE
codes and REPEAT Quick
Test.
this Pinpoint Test.
• Measure resistance between test pin 37/57 (gas),

test pin 71, 97 (diesel) at Breakout Box and
electronic pressure control power circuit at
(Diesel) at Breakout Box and electronic pressure
control pin at transmission connector.

ALL RIGHTS RESERVED
PINPOINT TEST E: EPC SOLENOID (Continued)

E3 I CHECK HARNESS FOR SHORT TO POWER OR
GROUND
• Turn ignition switch off. Yes ~ GOto E4.

007-00033 is installed, powertrain control module is
disconnected. RECONNECT all
• Make sure transmission connector is disconnected. components. REPEAT
this Pinpoint Test.
• Measure resistance between electronic pressure

control circuit test pin 38 or 81 (Diesel) and test pin
37/57 (gas), test pin 71, 97 (diesel) at the Breakout
Box.
• Measure resistance between electronic pressure
control circuit test pin 38 or 81 (diesel) and test pins
40/60, 46 or 77 1103, 91 (diesel) at the Breakout
Box.
E4 I TRANSMISSION FUNCTIONAL TEST
• Make sure the transmission harness connector is
disconnected.
Yes ~ REPLACE powertrain
control module. REPEAT
• Intaliline pressure gauge at line tap on case. Quick Test.
• Install Transmission Tester 007 -0085C. No ~ GOtoE5.
• Set BenchlDrive switch to DRIVE mode.
••
Rotate gear selector switch to 1st gear position.
Using tests outlined under Transmission Tester
Instructions, perform electronic pressure control
solenoid function test.
• Does electronic pressure control (LED GREEN)
activate when electronic pressure control switch is
depressed?
• Observe line pressure on gauge while depressing
electronic pressure control switch.
NOTE: Vehicle must be running.
• Does the line pressure drop?

E5 I CHECK RESISTANCE OF SOLENOID
CAUTION: Be sure that tester power is OFF or Yes ~ GOtoE6.
damage to volt-ohmmeter may result. No ~ REPLACE solenoid body
• Connect volt-ohmmeter negative lead to vehicle
power (VPWR) jack and positive lead to electronic
assembly. RECORD and
ERASE codes. REPEAT
pressure control (EPC) jack on tester. Quick Test.
- This is to test electronic pressure control
solenpid.
• Is the resistance between 3.0-5.0 ohms?
EPC
CONNECT VOM
ACROSS THESE JACKS.
< '£)VPWR
EPC PWR
0
STATUS
ACTIVATE
U EPC
D
D12552·A
1995 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain July 199..t

ALL RIGHTS RESERVED
PINPOINT TEST E: EPC SOLENOID (Continued)

E6 CHECK SOLENOID FOR SHORT TO GROUND
and appropriate jack with a volt-ohmmeter or other assembly. RECORD and
low current tester (less than 200 milliamps). ERASE codes. REPEAT
Quick Test.
Solenoid Tester Jack No ~ GO to Diagnosis by
Electronic Pressure Control Electronic Pressure Control Symptom Routine for
(EPC) diagnosis of electronic
Vehicle Power (VPWR) pressure control
concerns.
• Connection should show infinite resistance (no
continuity).
CONNECT YOM BETWEEN

THE SOLENOID JACKS
EPC
oBAT-
D12553-A
TD12550C
Pinpoint Test F - Coast Clutch Solenoi~ (CCS) This Pinpoint Test is designed to diagnose the
Diagnostic Trouble Codes: P1754/626 Coast
Clutch Solenoid Circuit Failure • Transmission Wiring Harness, coast clutch
This Pinpoint Test is designed to diagnosis the Coast solenoid, vehicle power (VPWR).
Clutch Solenoid electrical sy~tem ONLY. To prevent • Powertrain Control Module - 12A650 (gas) or
replacement of good components, note that the 12B565 (diesel).
following areas may be at fault:
Refer to the following schematic and charts when
• Electrical- Battery, input sensors, wiring performing the Pinpoint Test Steps.
harnesses
Coast Clutch Solenoid
TEST PIN 53 (DIESEL)

TEST PIN 55 0 BR - CCS
Powertrain Control Module
Solenoid TRANSMISSION
Signal Output Pin
VEHICLE
CCS 55 TEST PIN 37/570- R 1 : P W R HARNESS
TEST PIN 71,97 (DIESEL) CONNECTOR
53 (DIESEL)
FROM EEC
POWER
CCS =COAST CLUTCH SOLENOID
RELAY
VPWR =VEHICLE POWER
EEC =ELECTRONIC ENGINE CONTROL
D12555-8

ALL RIGHTS RESERVED
PINPOINT TEST F: CCS SOLENOID

F1 I E40D ELECTRONICS DIAGNOSTICS
connector is fully seated, terminals are fUlly
Yes ~ REMAIN in Output State
DTM. GO to F2.
engaged in connector and in good condition before No ~ DEPR'ESS throttle and
proceeding. RELEASE. If vehicle still
does not enter Output
State DTM, REFER to
• Connect Super Star II Tester 007 -0041 B or
equivalent.
Powertrain
Control/Emissions
• Perform KOEO TEST until continuous memory DTC
Diagnosis Manual. 14
••
Depress throttle to wide open throttle and release.
Does vehicle enter Output State DTM?
F2 I CHECK ELECTRICAL SIGNAL OPERATION
CAUTION: Remove heat shield from transmission Yes ~ GOto F5.
before r~moving connector. Remove ~olenoid Body No ~ GOto F3.

this Pinpoint Test.
• Connect volt-ohmmeter positive test lead to vehicle

power (VPWR) circuit and negative test lead to
solenoid circuit of transmission vehicle harness
connector.
• Place volt-ohmmeter on 20 volt scale.
• While observing volt-ohmmeter, depress and
release throttle several times to cycle solenoid
output On and Off.
• Does the suspected solenoid output voltage
change at least 0.5V?
F3 ICHECK CONTINUITY OF SOLENOID SIGNAL AND
VEHICLE POWER HARNESS CIRCUITS
•
~
Turn ignition switch off.
Make sure transmission harness connector is
Yes ~ GOto F4.
RECONNECT all
components. REPEAT
wires. Quick Test.
007-00033 or equivalent, leave powertrain control
this Pinpoint ~est.

module signal test pin 55 or 53 (diesel) at Breakout
connector.
• Measure resistance between test pin 37/57 or 71,
97 (diesel) at Breakout Box and vehicle power pin at


ALL RIGHTS RESERVED
PINPOINT TEST F: CCS SOLENOID (Continued)

F4 ICHECK SOLENOID HARNESS FOR SHORTS TO
POWER AND GROUND

Yes
No
~ GO to F5.
~ SERVICE short circuit.
NOTE: Refer to the schematic and charts preceding RECONNECT all
this Pinpoint Test. components. REPEAT
Quick Test.
module signal output pin and test pin 37/57 or 71,
97 (diesel) at the Breakout Box.
• Measure resistance between test pin 40/60 and 46
or 77 / 103 and 91 (diesel) at Breakout Box and
chassis ground.
F5
I SOLENOID FUNCTIONAL TEST
Yes ~ GOtoF6.
No ~ GOto F7.
• Install Rotunda Transmission Tester 007-00a5C or
equivalent.
• Using tests outlined under Tester Instructions
Perform the Solenoid Voltage Test.
NOTE: LED will turn GREEN when solenoid
activates and turn OFF when deactivated. LED will
turn RE D if activated solenoid is shorted to B+. LED
will remain OFF if an activated solenoid is shorted
to ground or no continuity.
• Do solenoids activate? (LED GREEN).

F6 I TRANSMISSION DRIVE TEST
• Perform Transmission Solenoid Cycling and Drive
Test Procedures as outlined under Transmission
Yes ~ .ERASE all codes and
PERFORM Drive Cycle
Tester Instructions in this section. Test in this section.
• Does Coast Clutch Solenoid activate when
commanded by the tester?
REPEAT Quick Test.
No ~ GO to F7.
•• Does engine braking occur?
Does the coast clutch engage?
F7 I CHECK RESISTANCE OF SOLENOID
••
Set Bench/Drive switch to BENCH mode. Yes ~ GOto F8.
Rotate gear select switch to OHMS. CHECK
No ~ REPLACE solenoid body
position. assembly.
• Connect a volt-ohmmeter negative lead to coast
clutch solenoid jack and positive lead to vehicle
power (VPWR) jack on tester.
••
Record resistance.
Resistance should be between 20-30 ohms.
• 18 resistance between 2~30 ohms?
ccs
ACROSSCONNECT VOM
THESE JACKS < :D VPWR
0
STATUS
ACTIVATE
"()~
CCC D
D12&68-A

ALL RIGHTS RESERVED
PINPOINT TEST F: CCS SOLENOID (Continued)

Fa CHECK SOLENOID FOR SHORT TO GROUND
and appropriate jack with or other low current tester assembly.
(less than 200 milliamps). ~ GO to Diagnosis by
No
Symptom section for
Solenoid Tester Jack coast clutch concerns.
Coast Clutch Solenoid Coast Clutch Solenoid (CCS)
• Connection should show infinite resistance (no

continuity).
• 18 there continuity?
CONNECT VOM BETWEEN

THE SOLENOID JACKS
ccs
oBAT +
0 BAT-
D12667-8
T012554C
Line Pressure Test

CAUTION: Perform line pressure test prior to
performing stall speed test. If line pressure is low
at stall, do not perform stall speed test or further
transmission damage will occur. DO NOT
MAINTAIN WIDE OPEN THROTTLE in any gear
range FOR MORE THAN FIVE (5) SECONDS.
This test verifies the line pressure is within
specifications.
1. Connect pressure gauge to line pressure tap.
PRESSURE
GAUGE
T57L-n820-A
D9248-C
2. Start engine and check line pressures. Refer to

the following chart to determine if line pressure is
within specification.
3. If line pressure is not within specifications,
perform On-Board Diagnostics and Pinpoint Test,
air pressure check and service main control
system or pump as required.
1995 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain, DrIvetrain July 1994
/ DAVE GRAHAM INC. - 2014

ALL RIGHTS RESERVED
I
J
1
DIAGN . IS AND TESTING (Continued)
LINE PRESSURE SPECIFICATIONS

Line Pressure - Idle Line Pressure - Stall
Gear KPA PSI KPA PSI
P,N 379-448 55-65 - -
R 517-683 75-99 1655-1827 240-265
€),2 379-448 55-65 1076-1200 156-174
1 517-683 75-99 1082-1282 157-186
Line Pressure Test

Low at Idle In All Ranges High at Idle In All Ranges
Check low fluid level, restricted inlet filter, loose main body, solenoid Check main regulator valve, solenoid body and wiring harness. Run
body or accumulator body-to-case bolts, excessive leakage in Quick Test referred to in electrical diagnosis in this section.
pump, case, control bodies, sticking main regulator valve,
damaged filter assembly and seal, damaged gaskets or valve body
separating plate.
Low Only In
P R N () 2 1
Check valve bodies Check separator Check valve bodies Check forward Check forward Check forward
7A100 reinforcing plate, 7A100 clutch, valve bodies clutch, coast clutch clutch, low / reverse
coast clutch, 7A100 or intermediate band clutch or coast
low / reverse clutch servo, valve bodies clutch, valve bodies
or direct clutch, 7A 100, 7G422 7A100
valve bodies 7A 100,
7G422
10125658
Torque Converter Drainback Test

1. Drive the vehicle for 30-60 minutes to attain
normal operating temperature.
2. Check the transmission fluid level. Only add fluid if
required.
3. Drive the vehicle through 8 to 10 cycles of 1/2
throttle, 1-2 upshifts to elevate transmission
temperature. Then proceed as follows:
• Park the vehicle on level ground.
• Allow the vehicle to sit for 30-60 minutes.
~!tj~QON'T ADD IF IN (
• Check and note fluid level on the dipstick with
the engine OFF, in PARK.
--4 ~1/4.
4. Allow the vehicle to sit for a minimum of 24 hours. I
FLUID LEVEL AFTER 45 MINUTES
5. Check and note fluid level as described in Step
No.3. If the fluid has risen 1 inch or more above
the level in the first check, excessive converter
drainback has occurred.
6. If excessive converter drainback has occurred,
TB-1743-A
replace drainback check valve at rear case fitting
and repeat test.

ALL RIGHTS RESERVED
~I.iitl11I_1i1lIF IN l
1- 1 112
- "_
1-112" -1/4" =1-1/4" /
FLUID LEVEL AFTER

24 HOURS
TB-1744-A
Stall Speed Test • Overdrive one-way clutch

WARNING: APPLY THE SERVICE AND PARKING • Direct clutch
BRAKES FIRMLY WHILE PERFORMING EACH • Engine performance
STALL TEST.
1. Connect tachometer to engine.
CAUTION: Perform line pressure test prior to
performing stall test. If line pressure is low at 2. After testing each of the following ranges, 0, 2,
stall, do not perform stall test or further 1 and R, move gearshift selector lever to N
transmission damage will occur. (neutral) and run engine for about 15 seconds to
allow torque converter (7902) to cool before
NOTE: The stall test should only be performed with the testing next range.
engine and transmission at normal operating
temperatures. 3. CAUTION: Do not maintain Wide Open
Throttle (WOT) in any gear range for more
The stall test checks the operation of the following than five seconds.
items:
Press accelerator pedal to floor (WOn in each
• Torque converter one-way clutch range. Record rpm reached in each range. Stall
• Forward clutch speeds should be in appropriate range.
• Low one-way clutch CAUTION: If engine rpm recorded by the
tachometer exceeds maximum specified rpm,
• Reverse clutch release accelerator pedal immediately. Clutch or
band slippage is indicated.
Series Axle Engine Min Max

F-150, LD F-250 3.08/3.31/3.55 ~ 4.9L 1590 1906
F-150, LD F-250 3.55/4.10 5.0L 2068 2490
Bronco 3.55/4.10 5.0L 2068 2490
F-150 4.10 5.8L HP 2287 2742
F-150, LD F-250 3.08/3.55/4.10 5.8L 2269 2707
Bronco 3.08/3.55/4.10 5.8L 2269 2707
HD F-250/350 3.55/4.10 5.8L 2248 2696
HD F-250/350 3.55/4.10 7.3L 01 Turbo Diesel 1938 2272
F-Super Duty 5.13 7.3L 01 Turbo Diesel 1938 2272
HD F-250/350 3.55/4.10 7.5L 1943 2315
F-Super Duty 4.63/5.13 7.5L 1943 2315

ALL RIGHTS RESERVED
If the stall speeds were too high, refer to the following 4. After normal operating temperatures are
Stall Speed Diagnosis Chart. If the stall speeds were reached, maintain a constant vehicle speed of
too low, first check engine tune-up. If engine is OK, about 80 km / h (50 mph), and tap the brake pedal
remove torque converter and check torque converter (2455) with the left foot.
reactor one-way clutch for slippage. 5. Engine rpm should increase when the brake pedal
is tapped, and decrease about five seconds after
STALL SPEED DIAGNOSIS CHART the brake pedal is released. If this does not occur,
Range Possible Source refer to Torque Converter Operation Concerns in
the Diagnosis by Symptom Charts.
() • Forward Clutch
• Overdrive One-Way Clutch 6. If the vehicle stalls in ~ at idle with the vehicle at
• Low One-Way Clutch a stop, move the gearshift selector lever to the
R
manual 1 position. If the vehicle stalls, the cause
• Direct Clutch
• Overdrive One-Way Clutch and Coast may be the converter control valve in the pump.
Clutch Service as required. If the vehicle doesn't stall in
• Reverse Clutch manual 1, refer to the Electrical Diagnosis for
2
powertrain control module (PCM)( 12A650) and
• Forward Clutch
• Overdrive One-Way Clutch and Coast Vehicle Harness Diagnosis.
Clutch
1 • Forward Clutch
• Reverse Clutch and Low One-Way Clutch
• Coast Clutch and Overdrive One-Way Shift Point Tests
Clutch
This test verifies that the shift control system is
operating properly.
1. Bring engine and transmission up to normal
Torque Converter Clutch Test operating temperature.
This test verifies the torque converter clutch control 2. Operate the vehicle with the gearshift selector
system and the torque converter are operating lever in ~ range.
properly. 3. Apply minimum throttle and observe the speeds
1. Perform Quick Test as stated in the Powertrain at which the upshift occurs and the torque
Control/Emissions Diagnosis Manual. 15 Check converter (7902) engages. (Refer to Automatic
for a code 94, 62, 627, 628 or 629. Refer to the Transmission Special Specification Bulletin
pinpoint test for diagnosis. FPS-12180-94 for actual speed.)
2. Connect a tachometer to the engine.
3. Bring engine to normal operating temperature by
driving the vehicle at highway speeds for
approximately 15 minutes in ~ range.

1995~\150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
1995 E40D APPLICATIONS SHIFT SPEEDS - APPROXIMATE· MPH

Throttle Opening Range Shift Vehicle Speed (1)
Light Throttle
~,o 1-2 8-13
,0 2-3 16-24
~
3-4 32-50
4-3 28-46
~.o
,0
3-2
2-1
12-17
5-9
Wide-Open Throttle
~.o
,0
1-2
2-3
20-40
37-70
8.~
3-4 56-108
4-3 51-103
0 3-2 31-71
,0 2-1 17-35
• (1) Nominal shift speed at sea level is shown. Actual shift speed will depend on tire brand, size and axle ratio.
NOTE: D is the same as €) with the transmission control switch actuated (light on).
10151268
4. With the vehicle in OVERDRIVE (fourth gear), Example: When the gearshift selector lever is in a
depress the transmission control switch. The forward gear range (€), 2, 1) a no-drive condition may
transmission should downshift to third gear. be caused by an inoperative forward clutch.
Remove foot from accelerator pedal; engine Perform the following procedures:
braking should occur.
1. Drain the transmission fluid. Remove transmission
5. Depress accelerator pedal to floor (wide-open oil pan (7A 194).
throttle). Transmission should shift from third to
second gear, or third to first depending on vehicle 2. Remove filter assembly and seal solenoid body
speed. Torque converter clutch should disengage and the control assemblies.
and then reapply. 3. The inoperative clutches may be located by
6. With vehicle €) range above 80 km / h (50 mph) applying air pressure into the appropriate clutch
and less than half throttle, move the transmission port. See diagram for clutch port locations.
gearshift selector lever from €) range to manual 2 4. Apply air pressure to the appropriate clutch port
range and remove foot from accelerator pedal. (see diagram). A dull thud may be heard, or
The transmission should immediately downshift movement felt when a clutch piston is applied. If
into second gear. With the vehicle remaining in clutch seals or check ball are leaking a hissing
manual 2 range, move transmission gearshift may be heard.
selector lever into manual 1 range, and release
accelerator pedal. Transmission should downshift
into first gear at speeds BELOW 48-56 km / h
(30-35 mph).
7. If transmission fails to upshift / downshift or torque
converter clutch does not apply and release,
refer to Diagnosis by Symptom charts for
concern diagnosis.
Air Pressure Tests

A no-drive condition can exist, even with correct
transmission fluid pressure, because of inoperative
clutches or bands. Refer to the Clutch / Band
application chart to determine the appropriate
elements. A clutch concern may be located through a
series of checks by substituting air pressure for fluid
pressure to determine the location of the malfunction.

ALL RIGHTS RESERVED
Air Pressure Test Part Locations
LOCATION OF
AIR PRESSURE CHECKS
09149-0
Part Part
1 - Reverse Clutch Feed 5 - Over Drive Clutch Feed
2 - Rear Lube 6 - Forward Clutch Feed
3 - Intermediate Lube 7 - Coast Clutch Feed
4 - Intermediate Clutch Feed 8 - Direct CI~tch Feed
(Continued)
CLUTCH/BAND APPLICATION CHART NO. 601

Inter-
medl- Inter-
() first - eb
- - - apply - HOLD eb
- - HOLD O/R
€) - eb
- apply - apply - HOLD ab
HOLD O/R O/R O/R
second
€) - eb
- apply apply apply - HOLD eb
O/R O/R O/R O/R
third
€) - - apply apply apply apply - O/R O/R O/R O/R O/R O/R
fourth
1 - apply - - - apply apply HOLD CC - - HOLD -
(Continued)

ALL RIGHTS RESERVED
CLUTCH/BAND APPLICATION CHART NO. 601 (Cont'd)

Inter-
madl- Inter-
2 apply apply - apply - apply - HOLD CC HOLD BA O/R O/R
reverse - apply - - apply - apply HOLD CC O/R O/R - -
a In €) Range with the Transmission Control Switch pressed, the coast clutch is applied and the 0/ D one-way clutch is bypassed.
b On certain applications in 0/0 range, the cloast clutch solenoid and clutch is controlled by the PCM.
0/ D - Overdrive
OWC - One-Way Clutch
O/R - Overrunning
CC - Coast Friction Clutch Applied
BA - Band Applied
TD15124A
IN-VEHICLE SERVICE
Extension Housing Seal and Bushing

Seal Remover T74P-77248-A
Extension Housing Bushing Remover T77L-7679-D
Extension Housing Bushing Replacer T77L-7697-C
Extension Housing Seal Replacer T61L-7657-B
Removal
1. Raise vehicle on a hoist and position suitable
safety stands under vehicle.
2. Remove rear driveshaft. Refer to Section 05-01.
3. Remove extension housing seal using Seal
Remover T74P-77248-A and Impact Slide
Hammer T50T-1 OO-A.

ALL RIGHTS RESERVED
4. CAUTION: Do not damage any machined

surfaces. 12 O'CLOCK
Remove the extension housing bushing (7A034)

using Extension Housing Bushing Remover
T77L-7679-D.
D10878-A
3. Install extension housing bushing using Extension

Housing Bushing Replacer T77L-7697-C.
D10075-A
Installation
1. Inspect the counter bore of the extension housing
(7A039) for burrs. If necessary, remove burrs
with an oil stone.
2. Align lubrication slots in the extension housing
bushing with groove in extension housing (6
o'clock).
D10677-A

ALL RIGHTS RESERVED
4. Position new extension housing seal with drain 7. Install driveshaft as outlined in Section 05-01.
hole positioned downward (6 o'clock). 8. Remove safety stands and lower vehicle.
12 O'CLOCK
Extension Housing Gasket

Removal
1. Raise vehicle on hoist and position suitable safety
stands under vehicle.
2. Remove front (4x4 only) and rear driveshaft.
3. Remove parking brake assembly. Refer to Body,
Chassis Manual, Section 06-05.
4. Remove transfer case assembly (4x4 vehicle).
Refer to Section 07-07A or 07-07B.
5. Remove transmission mounting pad nuts and
bolts. Refer to the transmission removal
procedures for crossmember illustrations.
6. Carefully remove wire harness locators from
6 O'CLOCK
extension housing wire bracket.
7. Position jack under transmission and raise
D10678·A transmission.
5. Seat extension housing seal using Extension 8. Remove nine extension housing bolts using a
Housing Seal Replacer T61L-7657-B. 13mm wrench. Remove wiring bracket.
EXTENSION
HOUSING
7A039
9. Remove and discard extension housing gasket

EXTENSION HOUSING (7086) from extension housing (7A039) and
SEAL REPLACER mating surfaces.
T61L-7657-B
D10679-A
6. Inspect driveshaft slip yoke. Replace if damaged

or worn.

ALL RIGHTS RESERVED
07·01A·106 Transmission, Automatic, E40D 07-01A-106
Installation 8. Remove universal high lift transmission jack.

1. Clean extension housing and case mating 9. Install front (4x4 only) and rear driveshaft. Refer
surfaces. Place a light film of petroleum jelly on to Section 05-01 .
the extension housing gasket and position gasket 10. Fill the transmission to the proper level with
on the extension housing. Motorcraft MERCON@ Multi-Purpose Automatic
Transmission Fluid XT-2-QOX or MERCON@
EXTENSION equivalent.
HOUSING
GASKET
7086
Main Control Valve Body
NOTE: If a transmission has been disassembled to
replace worn or damaged parts and the valves in the
main control valve body (7A 100) stick repeatedly from
foreign material, the torque converter (7902) must be
removed and cleaned by using a mechanically agitated
cleaner, such as Rotunda Torque Converter I Oil
Cooler Cleaner 014-00028 or equivalent.
Removal
1. Loosen the two transmission heat shield bolts
using an 8mm socket. Remove the transmission
D92Q9.C
heat shield (7A434).
2. NOTE: Make'sure parking pawl return spring 2. CAUTION: Do not attempt to pry tab with pry
(70070) is fully seated into the case (7005) prior bar or screwdriver. Remove the transmission
to installing extension housing. heat shield from the transmission before
Raise extension housing into position. Position
attempting to remove the connector.
wiring bracket. NOTE: Check electrical connectors for terminal
condition, corrosion and contamination. Repair or
3. Install nine extension housing bolts using a 13mm
replace as required.
socket. Tighten to 27-39 N·m (20-29 Ib-ft) on 4x2
applications, or to 33-54 N·m (24-40 Ib-ft) for 4x4 Remove solenoid body assembly connector by
applications. pushing on the center tab and pulling on the wire
harness.
4. On 4x4 models only, attach transfer case vent

hose to detent plate. Refer to Section 07-07A or
07-078.
5. Install four-wheel drive connector, if equipped.
6. Install new wire harness locator into extension
housing wire bracket. 3. Position a drain pan under transmission.
7. Install transmission mounting pad bolts and nuts
and tighten to 82-109 N·m (60-80 Ib-ft).

ALL RIGHTS RESERVED
4. Remove all transmission pan bolts except the

front ones using a 10mm socket. Loosen only the
front bolts at this time. SEAL (PART OF 7A098)
TRANSMISSION
OIL PAN
7A194
D9216-C
8. Remove 11 accumulator body bolts using an

8mm socket and two nuts using a 10mm socket.
D8954-D Remove accumulator body assembly.
5. Pry the rear of the transmission oil pan (7A 194)

down and allow the fluid to drain.
6. Remove front pan bolts using a 10mm socket.
Remove transmission oil pan.
7. CAUTION: Use care not to scratch or damage
aluminum pump bore.
Remove filter assembly and seal by carefully
pulling and rotating the filter as necessary. If seal
remains in bore, carefully remove using a small
screwdriver. Discard filter assembly and seal.
SEAL
(PART OF 7A098)
ACCUMULATOR BODY
ASSEMBLY /
76422 09217-8
FILTER
(PART OF 7A098)
D9215-E

ALL RIGHTS RESERVED
9. If valve body separating plate (7 A008) is to be 11. Remove nine solenoid body assembly bolts using
left on the transmission, use one of the reinforcing a T30 Torx@ bit and one nut using a 10mm socket.
plate bolts in the hole shown to prevent front of Push down on solenoid body assembly
valve body separating plate from sagging and receptacle to remove solenoid body assembly.
displacing check balls.
o 0000 c:::J00
o 0°0 0
° 00
INSTALL REINFORCING PLATE BOLT

HERE TO SECURE PLATE AND
MAINTAIN BALL LOCATIONS IF
BODIES ARE REMOVED AND PLATE IS
LEFT ON TRANSMISSION D8582-e SOLENOID BODY
ASSEMBLY
10. NOTE: Do not remove the two bolts as shown on 76391 D9219-C
illustration. This will keep the upper and lower
main control valve bodies attached as an 12. Remove solenoid screen assembly by rotating
assembly. and pulling it out.
Remove 14 main control valve body bolts using
an 8mm socket and two nuts using a 10mm SOLENOID
socket. Remove main control valve body. SCREEN ASSEMBLY
7G308
v
Q) 0 a
o
o
09220-0

ALL RIGHTS RESERVED
13. R~move separator plate reinforcing plate bolts

uSing an 8mm socket. Remove plate. SERVO
PISTON
SPRING
70028
- INTERMEDIATE
BAND SERVO
INTERMEDIATE SERVO RETAINER
PISTON RETAINING RING 78264
7381
\
D9223-E
Installation
SEPARATOR PLATE 1. Install the servo piston spring, intermediate band
REINFORCING PLATE servo piston and intermediate band servo
7F282 retainer.
2. Depress the intermediate band servo retainer and
D922100C install the intermediate servo piston retaining ring.
3. Apply a .light film of petroleum jelly to valve body
14. Lower valve body separating plate and gaskets separating plate to hold new main control to case
carefully so that rubber check balls, steel EPC gasket (7C155).
check ball and spring are retained.
SEPARATING PLATES SEPARATING PLATE TO CASE

AND GASKETS GASKET-7C155
VALVE BODY
SEPARATING
PLATE
7AOOB
MAIN CONTROL
TO SEPARATING
PETROLEUM PLATE GASKET
JELLY 70100 D9224-E
D9222·C
4. Apply liqht film of petroleum jelly to valve body
15. Depress the intermediate band servo retainer and separating plate to hold new main control to
r~move the inter~ediate servo piston retaining separating plate gasket on valve body separating
ring. Remove the Intermediate band servo plate.
retainer, intermediate band servo piston (70021)
and servo piston spring (70028). '

ALL RIGHTS RESERVED
5. Place a small amount of petroleum jelly on each of

the nine rubber check balls and the steel EPC
check ball. Position balls on the valve body
separating plate as shown.
STEEL EPC CHECK

(1 REO'D)
o 0 - 0 0
RUBBER CHECK BALL

(9 REO'D)
D9225-E
6. Place a daub of petroleum jelly onto the EPC ball

spring assembly. Install them into their locations
as shown.
D904D-G

ALL RIGHTS RESERVED
7. Install separator plate reinforcing plate using 9. Install main control valve body over studs. Align
three separator plate reinforcing plate bolts. manual shift valve (7C389) with manual valve
lighten to 9-11 N·m (80-100 Ib-in). detent lever (7A 115).
a. Check location of rubber check balls and
steel EPC check ball. MANUAL VALVE
DETENT LEVER
7A115 MAIN CONTROL
SEPARATOR PLATE VALVE BODY
REINFORCING PLATE 7A100
7F282
TIGHTEN BOLTS TO
9-11 N-m
(80-100 LB-IN)
D9227-e 10. NOTE: If separator plate reinforcing plate bolt

has been used to retain valve body separating
plate to case (7005), reinstall after main control
b. If separator plate reinforcing plate bolt has
valve body is attached.
been used to retain valve body separating
plate to case, do not reinstall in separator Attach main control valve body with two nuts
plate reinforcing plate until Step 10. using a 10mm socket and 14 bolts using an 8mm
socket. lighten to 9-11 N·m (80-100 Ib-in).
c. The "UP" stamped on separator plate
reinforcing plate must be visible.
8. Install solenoid screen assembly and rotate to
lock in place.
SOLENOID
SCREEN ASSEMBLY
7G308
u
1\
~ 0
0
0
0 0

ALL RIGHTS RESERVED
11. Install accumulator body assembly over studs 13. Install a new filter assembly and seal by
and attach with two nuts using a 10mm socket lubricating the seal with transmission fluid and
and 11 bolts using an 8mm socket. lighten to pressing the filter into place. Do not reuse old
9-11 N·m (80-100 Ib-in). filter or seal.
SEAL
(PART OF 7A098)
D9230-B
12. NOTE: Prior to solenoid body assembly

installation, coat the case connector bore with FILTER
Disc Brake Caliper Slide Grease D7AZ-19590-A (PART OF 7A098)
or equivalent meeting Ford specification D9215-E
ESA-MIC172-A.lnspect solenoid body assembly
electrical connector for proper seating and 14. Check for correct placement of oil pan magnet
condition. over dimple in transmission oil pan. Install new oil
pan to case gasket (7A 191).
NOTE: The solenoid body for 1995 has unique
features and will not service past models.
Install solenoid body assembly over stud and
attach with nine Torx@ bolts using a T30 bit and o o o
one nut using a 10mm socket. Tighten to 9-11
N·m (80-100 Ib-in).
o o c
OIL PAN OIL PAN TO
MAGNET CASE GASKET
LOCATION 7A191
09232-8

ALL RIGHTS RESERVED
15. Install pan bolts using a 10mm socket. Tighten to

14-16 N·m (10-12Ib-ft).
TIGHTEN
BOLTS TO
14-16 N-m
(10-12 LB-Fr) D9233-C TIGHTEN BOLTS
TO 9-11 N-m
(80-100 LB-IN)
16. Completely seat solenoid body connector into 09196·0
solenoid body assembly receptacle by pushing on
top of connector. Audible click indicates full 18. Lower vehicle.
connection.
19. Fill the transmission to the proper level with
Motorcraft MERCON@ Multi-Purpose Automatic
Transmission Fluid XT-2-QDX or MERCON@
equivalent.
Manual Lever Seal

Locknut Pin Remover T78P-3504-N
Shift Lever Seal Replacer T74P-77498-A
MLP Alignment Tool T92P-700 10-AH
Removal
1. Remove shift cable or linkage from manual
control lever (7A256). Use a screwdriver and
remove the cable and fitting from 1he manual
control lever ball stud.
17. Install transmission heat shield with off-set

bending inward. lighten bolts to 9-11 N·m
(80-100Ib-in).

ALL RIGHTS RESERVED
2. Place a drain pan under the transmission oil pan 6. CAUTION: Use care not to scratch or damage
(7A 194). Remove rear and side transmission fluid aluminum pump bore.
pan bolts using a 10mm socket. If seal remains in bore, carefully remove using a
screwdriver.
TRANSMISSION
OIL PAN
7A194
SEAL (PART OF 7A09a)
D8954-D
D9216-C
3. Loosen the front pan bolts using a 10mm socket.
Pry the rear of the transmission oil pan from the 7. CAUTION: Do not damage any machined
case and allow fluid to drain. surfaces.
4. Remove front pan bolts using a 10mm socket. NOTE: A number 53 drill bit (1/ 16-inch) may be
Remove transmission oil pan. used as an alternative method to remove the
5. NOTE: Seal may remain in bore when filter manual lever shaft retaining pin (78210).
assembly is removed. Remove manual lever shaft retaining pin using
Remove filter assembly and seal by carefully Locknut Pin Remover T78P-3504-N.
pulling and rotating filter as necessary. Discard
filter assembly and seal.
SEAL
(PART OF 7A09a)
I
\
\ .
LOCKNUT
PIN REMOVER
T78P-3504-N
MANUAL LEVER
SHAFT RETAINING PIN
FILTER
78210 D9234-E
(PART OF 7A09a)
D9215-E 8. Remove inner manual valve detent lever nut using
a 21 mm box wrench while holding manual lever
assembly with a crescent wrench.

ALL RIGHTS RESERVED
9. Remove manual valve detent lever and parking

lever actuating rod assembly from manual control
lever shaft (7C493).
10. Remove outer manual control lever shaft nut using
a 15mm open end wrench while holding manual
control lever with crescent wrench.
11. NOTE: After removal, discard outer manual
control lever shaft nut. Do not reuse.
Remove manual control lever.
12. Disconnect transmission range (TR) sensor
connector by squeezing connector tabs and
pulling on connector harness. Check connector
for terminal condition, corrosion and
contamination. Check connector seal for
damage. Repair or replace as required.
13. Remove two TR sensor bolts and washers using
an 8mm socket and'remove sensor.
14. Remove manual control lever shaft.
15. CAUTION: Use care not to damage the
09237·8
manual control lever shaft bore.
Remove manual control lever shaft seal (7F337)
2. Install manual control lever shaft.
using Seal Remover T74P-77248-A and Impact
Slide Hammer T50T-100-A. 3. NOTE: Manual valve detent lever (7A 115) must
be seated on flats of manual control lever shaft.
Parking lever actuating rod (7A232) must be
through guide plate. Detent lever pin must be
properly engaged with manual shift valve
(7C389).
Install manual valve detent lever, parking lever
actuating rod and nut.
4. lighten inner manual valve detent lever nut using
a 21 mm crowfoot while holding manual control
lever shaft with crescent wrench. lighten nut to
41-54 N·m (30-40 Ib-ft).
TIGHTEN NUT TO
41-54 N-m
(30-40 LB-FT)
I
MANUAL CONTROL
LEVER SHAFT
SEAL-7F337 D10681-C
Installation
1. Clean bore opening with mineral spirits. Install
manual control lever shaft seal using Shift Lever
Seal Replacer T74P-77498-A.
INNER MANUAL VALVE

DETENT LEVER NUT
09238-0

ALL RIGHTS RESERVED

transmission fluid pan sealing surface. SEAL
(PART OF 7A098)
Install manual lever shaft retaining pin past case
surface.
6. Install TR sensor with two bolts and washers. Do
not tighten bolts at this time.
7. Align transmission for neutral gear position using
Transmission Range (TR) sensor (MLP)
Alignment Tool T92P-70010-AH.
8. CAUTION: The TR sensor connector seal is
located in the vehicle harness connector for
1995. Do not use past model TR sensors to
servio 1995 TR sensor.
Using an 8mm socket, tighten bolts to 6-8 N·m
(55-75Ib-in).
9. NOTE: After connecting TR sensor connector,
verify connection by pulling on harness.
Install TR sensor harness connector. Audible click FILTER
(PART OF 7A098)
indicates full connection.
D9215-E
10. NOTE: The manual control lever must be seated
on the flats of the manual control lever shaft. 15. Using a light coat of petroleum jelly to hold the
Install the manual control lever onto the manual new oil pan to case gasket (7A 191), position oil
control lever shaft. pan to case gasket onto transmission oil pan.
11. CAUTION: A new outer manual control lever Clean and check condition of oil pan magnet.
shaft nut must be used to properly secure Position oil pan magnet over dimple in
manual control lever to manual control lever transmission oil pan.
shaft.
Install a new outer manual control lever shaft nut
using a 15mm socket while holding the manual o
control lever with a crescent wrench. Tighten the
nut to 27-39 N·m (20-29Ib-ft).
12. Install shift cable onto the manual control lever.
Use a screwdriver to press cable end fitting over
transmission manual control lever ball stud.
13. Shift manual control lever to all detent positions to
check proper engagement of all positions and
parking mechanism.
14. NOTE: Do not reuse old filter assembly or seal.
Install new filter assembly and seal by lubricating
seal with transmission fluid and pressing filter into
place. 0> o o
OIL PAN OIL PAN TO

MAGNET CASE GASKET
LOCATION 7A191
09232-8
16. Install transmission oil pan and bolts using a

10mm socket. Tighten bolts to 14-16 N·m ( 10-12
Ib-ft).
17. Remove safety stands and lower vehicle.
18. Fill the transmission to proper level with
equivalent.
19. Check shift cable adjustment. Refer to Section
07-05.

ALL RIGHTS RESERVED
07-011\-117 Transmission, Automatic, E40D 07-01A-117
Fluid Cooler Lines

Transmission Fluid Cooler Tubes, F-Serles and Bronco (Except 4.9L Engine)
D7892·C
Part Part
1 372223 C-Clip 11 7F113 Inlet Tube (Auxiliary Cooler
2 7N291 Transmission Oil Cooler Line In)
Clip 12 - Cooler Tube Nut
3 70273 Oil Tube Connector (Part of 7F113)
4 7A031 Outlet Tube A - Tighten to 16-24 N·m
(12-18 Lb-F~)
5 7005 Case
6 7A030 Inlet Tube
(12-18 Lb-Ft)
7 7A095 Transmission Fluid Cooler -
Auxiliary
(25-35 Lb-In)
8 78093 Transmission Oil Cooler 0 - Tighten to 9-14 N·m
Hose (80-123 Lb-In)
9 376240 Clamp E - Tighten to 9-14 N·m
10 7F112 Outlet Tube (Auxiliary Cooler (80-123 Lb-In)
Out)
(Continued)

ALL RIGHTS RESERVED
Transmission Fluid Cooler Tubes, F-Super Duty Motorhome Chassis (Except Diesel)
VIEWY
D9954-D
Part Part
1 7A095 Transmission Fluid Cooler 14 6010 Cylinder Block
2 6K761 Oil Cooler Upper Bracket 15 7B147 Tube Bracket
3 W611101 Screw and Washer 16 W611101 Screw and Washer
4 6C645 Insulator A - Tighten to 7-10 N·m
5 55736 Nut (62-88 Lb-In)
6 7005 Case B - Tighten to 16-23 N·m
(12-16 Lb-Ft)
7 7A030 Inlet Tube
8 7A131 Outlet Tube
(16-22 Lb-Ft)
9 7D273 Oil Tube Connector D - Tighten to 22-30 N·m
10 N804771 Clip (16-22 Lb-Ft)
11 7Fl13 Inlet Tube E - Tighten to 28-32 N·m
12 376240 Clamp (20-23 Lb-Ft)
13 N809621 Hose (Continued)
(Continued)

ALL RIGHTS RESERVED
Part Part
F - Tighten to 3-4 N·m G - Tighten to 3-5 N·m
(25-35 Lb-Ft) (25-48 Lb-In)
(Continued)
Transmission Fluid Cooler Tubes, F-Super Duty Motorhome Chassis (Except Diesel)
VIEWZ
D11842-C
Part Part
1 W611102-S2 Screw and Washer 14 6K761 Oil Cooler Upper Bracket
2 372223 C-Clip A - Tighten to 7-10 N·m
3 7A031 Outlet Tube (5-7 Lb-Ft)
4 7A030 Inlet Tube B - Tighten to 16-24 N·m
(12-18 Lb-Ft)
6 7N291 Transmission Oil Cooler Line (12-18 Lb-Ft)
Clip
7 7F113 Inlet Tube
(12-18 Lb-Ft)
8 7D273 Oil Tube Connector E - Tighten to 25-30 N·m
9 376240 Clamp (18-22 Lb-Ft)
10 N809635 Hose F - Tighten to 3-4 N·m
11 55736 Nut (2-3 Lb-Ft)
12 7A095 Transmission Fluid Cooler G - Tighten to 16-23 N·m
13 6C645 Insulator (12-17 Lb-Ft)
(Continued)

ALL RIGHTS RESERVED
F-Series and Bronco (4.9L)
VlEWZ
D10059-C
Part Part
1 8005 Radiator 11 7Fl13 Inlet Tube
2 372223-856 C-Clip 12 7A095 Transmission Fluid Cooler
3 7A031 Outlet Tube A - Tighten to 16-24 N·m
4 7A030 Inlet Tube (12-18 Lb-Ft)
5 7N291 Transmission Oil Cooler Line 8 - Tighten to 16-24 N·m
Clip (12-18 Lb-Ft)
6 7A030 Inlet Tube C - Tighten to 16-24 N·m
(12-18 Lb-Ft)
7 376240-8 Clamp
8 78093 Transmission Oil Cooler
(25-35 Lb-In)
Hose
9 372223-856 C-Clip
(7-10 Lb-Ft)
10 7Fl12 Outlet Tube F - Tighten to 9-14 N·m

ALL RIGHTS RESERVED
F-250-350, F-Super Duty (7.3L)
VIEWY
010061-8
Part Part
1 372223-S56 C-Clip 11 W611101-S2 Screw and Washer
2 7A031 Outlet Tube 12 376240-S Clamp
3 7A030 Inlet Tube 13 7N291 Transmission Oil Cooler Line
4 376240-S 100 Clamp Clip
5 7890 Hose Assembly 14 33799 Nut, 3/8-16
6 8005 Radiator (735 Sq. In. - with 15 57643 Screw and Washer,
Auxiliary Cooler) 3/8-16x.62
7 78093 Transmission Oil Cooler 16 8005 Radiator (735 Sq. In. -
Hose Without Auxiliary Cooler)
8 - Connector (Part of 8005 17 8005 Radiator (585 Sq. In. -
Radiator) Without Auxiliary Cooler)
9 357946-S100 Clip A - Tighten to 12-18 N·m
(9-13 Lb-Ft)
10 78093 Transmission Oil Cooler
Hose (Continued)
(Continued)
1995 F-150, F-250, F-350, Bronco, F-S~per Duty Powertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
Part Part
B - Tighten to 12-18 N·m E - Tighten to 3-4 N·m
(9-13 Lb-Ft) (25-35 Lb-In)
C - Tighten to 3-4 N·m F - Tighten to 12-18 N·m
(25-35 Lb-In) (9-13 Lb-Ft)
(35-53 Lb-In)
(Continued)
F-Super Duty Commercial Chassis (7.3l)
MAIN VIEW
D10085-A
Part Part
1 7003 Transmission 9 7N291 Transmission Oil Cooler Line
2 7A030 Inlet Tube Clip
3 33799 Nut, 3/8-16 Hex 10 372223-S56 C-Clip
4 57643 Screw and Washer, 11 N809635-S276A Hose 7.9mm ID
3/8-16 x .62 Hex Head 12 - Connector
5 6010 Cylinder Block (Part of 8005 Radiator)
6 14301 Battery Ground Cable 13 8005 Radiator
(Reference Only) A - Tighten to 16-25 N·m
7 7A031 Outlet Tube (12-18 Lb-Ft)
8 376240-S Hose Clamp B - Tighten to 16-25 N·m
(12-18 Lb-Ft)
(Continued)
(Continued)

ALL RIGHTS RESERVED
Part Part
C - Tighten to 16-25 N·m 0 - Tighten to 2.8-4.0 N·m
(12-18 Lb-Ft) (25-35 Lb-In)
(Continued)
Parking Mechanism
PARKING
Removal PAWL SHAFT
1. Remove the extension housing gasket (7086) as 7D071
2. Remove two bolts using a 13mm socket and
remove parking rod guide plate.
PARKING
PAWL
7A441
D9213-D
Installation
To install, reverse the removal procedure.
Make sure spring end rests on inside surface of case.
Also make sure dimple on parking rod guide plate
faces inward when installed.
09212-0
Tighten parking rod guide plate bolts to 22-27 N·m
(16-20 Ib-ft).
3. Remove parking pawl return spring (70070),
parking pawl (7A441) and parking pawl shaft For internal park mechanism service, refer to manual
(70071) from case. lever seal removal and installation procedures in this
section.
REMOVAL
Transmission Fluid Drain and Fill Procedure

Normal maintenance and lubrication requirements do
not necessitate periodic automatic transmission fluid
changes. If a major service, such as a clutch, band,
bearing, etc., is required in the transmission, it will
have to be removed for service. At this time, the
converter, transmission cooler and cooler lines
must be thoroughly flushed to remove any
contamination.

ALL RIGHTS RESERVED
REMOVAL (Continued)
CAUTION: Use of a fluid other than specified 11. Remove muffler (5230) and tail pipe assembly
could result in transmission malfunction and/or (5.8L Lightning Truck applications only). On
failure. Diesel, remove exhaust crossover. Refer to
There is no scheduled automatic transmission fluid Section 09-00.
change requirement for E40D transmissions. 12. Remove nuts retaining three way catalytic
Transmission fluid level should be checked when converter (TWC)(5E212) to exhaust manifolds
performing other maintenance service and adjusted to (9430) (5.8L Lightning Truck application only)
specified levels. and let assembly rest on frame (5005).
The automatic transmission fluid, filter and seal 13. Loosen the two transmission heat shield bolts
assembly should be changed every 21,000 miles using an 8mm socket. Remove the transmission
under any of the following conditions: heat shield (7A434).
• Sustained high speed driving during hot weather at
or above +90°F (+30°C)
• Towing a trailer for distances over 1,000 miles
(1600Km)
• Accumulating 5,000 miles (8000 Km) or more per
month
• Continuous running service.
• When filling a dry transmission and converter start
with a minimum of 6. 1 liters (6.5 quarts). Refer to
Specifications for capacity. Check the fluid level.
Transmission
Torque Converter Handles T81 P-7902-C
Removal 09161·8
1. Disconnect battery ground cable (14301) at the
battery. 14. CAUTION: Do not attempt to pry tab with pry
bar or screwdriver.
2. Remove fluid level indicator (7A020).
Remove solenoid body assembly connector
3. Place transmission gearshift selector lever in carefully by pushing on the center tab and pulling
NEUTRAL position. on the wire harness.
4. Raise vehicle on a hoist and position suitable
safety stands under vehicle.
5. Remove skid plate (4x4 vehicles).
6. On 4x4 models only, remove front driveshaft.
Refer to Section 05-0 1.
7. Remove rear driveshaft. Refer to Section 05-01.
On F-Super Duty vehicles, remove the
transmission-mounted parking brake. Refer to
Section 06-05.
8. Disconnect shift cable, or linkage on F-Super
Duty Motorhome and Commercial vehicles. Refer
to Section 07-05.
9. On 4x4 models only, (mechanical shift systems)
remove shift linkage from transfer case shift
lever. Refer to Section 07-05. Disconnect
electrical connector at transfer case.
10. CAUTION: Do not attempt to pry tabs with
pry bar or screwdriver.
Remove Transmission Range (TR) sensor
connector by pushing center tab on connector
and pulling on connector.

ALL RIGHTS RESERVED
REMOVAL (Continued)
15. On 4x4 models only, remove four-wheel drive

switch connector from transfer case. Use care LOWER CONVERTER
CQVER-7986
not to overextend tabs.
16. Carefully pry wire harness locator from extension
housing wire bracket.
09168-8
19. Remove rear engine cover plate bolts.

Dl185-1A
17. On 4x4 models only, remove wire harness

locators from left side of rear engine support
(6A023).
20. Remove starter motor (11001). Refer to Section

03-06A or 03-068.
21. Remove converter housing access plug (7N 171).
Use a 15 / 16-inch socket to rotate crankshaft
18. Remove lower torque converter cover bolts using (6303) to gain access to the converter drain plug.
a 10mm socket and remove cover. Remove plug. Drain torque converter (7902).

ALL RIGHTS RESERVED
REMOVAL (Continued)
22. Rotate crankshaft bolt to gain access to

converter nuts. Using a 9/ 16-inch socket, 4 x 4 VEHICLES
remove four (six for 7.3L) converter mounting
nuts and discard.
09172-8
23. Place Rotunda E40D Transmission Adapter POSITIONING

014-00763 or equivalent on universal E40D TRANSMISSION PINS
transmission jack and position adapter as in ADAPTER
014-00763
following illustration.
D9174-C
Placement of Positioning Pins 24. Use a safety strap to secure transmission.

25. NOTE: Transmission may have to be raised to
4 x2 VEHICLES gain adequate clearance to remove rear engine
support.
Remove the two rear transmission mounting pad
nuts using an 18mm socket. Remove rear engine
support-to-frame bolts and remove rear engine
support from transmission.
POSITIONING
PINS
D9173-e

ALL RIGHTS RESERVED
07-01A-127 Transmission, Automatic, E40D 07-01A·127
REMOVAL (Continued)
Crossmember Installation, F-Series Vehicles
LIGHTNING TRUCK
F-15Q-350 (4x2) 4x2
•
VIEWY
F-150 - F-350, BRONCO (4x4)
AND F-SUPER DUTY
VIEWY VIEWZ
D9955-C
Part Part
1 6096 Rear Engine Support 6 N802114 Bolt
Bracket (LH) 7 6A023 Rear Engine Support
2 60091 Insulator and Retainer 8 N800937 Nut
3 388824 Screw and Washer 9 N621945 Nut and Washer
4 7108 Transmission Support A - Tighten to 59-77 N·m
Bracket (43-57 Lb-Ft)
5 6096 Rear Engine Support B - Tighten to 81-108 N·m
Bracket (RH) (60-80 Lb-Ft)
(Continued)

ALL RIGHTS RESERVED
REMOVAL (Continued)
26. NOTE: Case connector fitting should be held with 30. CAUTION: Torque converter is very heavy.
wrench to prevent it from moving when loosening NOTE: Fluid loss will occur when torque
tube nut. converter is removed.
Remove transmission fluid cooler tubes using a Install Torque Converter Handles T81 P-7902-C
1/ 2-inch flare nut wrench from transmission on torque converter with handles in the 6 and 12
case. Cap transmission fluid cooler tubes and o'clock positions. Carefully remove torque
plug fittings at transmission. The F-Super Duty converter from transmission by pulling evenly on
Motorhome Chassis requires the use of a handles.
5 /8-inch tube nut wrench.
TRANSMISSION OIL
COOLER TUBE
31. Remove oil filler tube (7A228) from lube oil inlet
short tube (7A 160).
32. On 4x4 models only, remove transfer case vent
hose from detent bracket.. Refer to Section
07-07A or 07-078.
27. Remove six torque converter housing bolts.
33. On 4x4 models only, remove the transfer case
28. Shift transmission to the left and remove three
from the transmission. Refer to Section 07-07A or
way catalytic converter from vehicle (5.8L
07-078.
Lightning Truck applications only).
29. Back out transmission assembly from flywheel
(6375) and gently lower while watching for any DISASSEMBLY
obstructions.
Transmission
Refer to the transmission disassembled view at the
beginning of this section.
NOTE: During disassembly and assembly of the
transmission, the "clock" numbers shown in the
following illustrations will be referred to in order to
reference the position in the transmission.

Pump Puller Adapter T89T-70010-A
Impact Slide Hammer T59L-100-B
Clutch Spring Fixture T89T-700 10-C
Clutch Remover / Replacer T89T-700 10-E
Extension Housing Seal Replacer T61L-7657-B
Locknut Pin Remover T78P-3504-N
Puller T58L-101-B

ALL RIGHTS RESERVED
DISASSEMBLY (Continued)
1. Mount transmission on Rotunda Car I Truck

Engine Repair Stand 014-00106 or equivalent
with the converter assembly removed.
ROTUNDA
CARITRUCK ENGINE
REPAIR STAND
014-00106 08952-8
D10682-c
2. CAUTION: The input shaft (7017) and
overdrive planet assembly are serviced as 4. CAUTION: Use care not to scratch or damage
mating components. Do not mix 1995 parts aluminum pump bore.
and prior year service parts. NOTE: After removal, discard filter assembly and
Remove input shaft from transmission. seal.
Remove filter assembly and seal by carefully
pulling and rotating filter as necessary. If seal
INPUT remains in bore, carefully remove using a
SHAFT 12 O'CLOCK screwdriver.
7017
r
ft O'CLOCK D8953-D
3. Rotate transmission so that transmission oil pan

(7A 194) is facing up. Remove 20 pan attaching
bolts using a 10mm socket. Remove the
transmission oil pan and oil pan to case gasket
(7A 191), discard oil pan to case gasket.

ALL RIGHTS RESERVED
5. Remove 11 accumulator body assembly bolts

using an 8mm socket and two nuts using a 10mm
socket.
MAIN CONTROL
VALVE BODY
7A10b
D8957-F
D8956-E
6. NOTE: Do not remove the two bolts as shown.

These two bolts hold the upper and lower main
control valve bodies together as an assembly.
Remove 14 main control valve body bolts using
an 8mm socket. Remove two nuts using a 10mm
socket.

ALL RIGHTS RESERVED
7. Remove nine solenoid body assembly bolts using 9. Remove solenoid screen assembly by rotating
a T30 Torx@ bit and one nut using a 10mm and pulling out.
socket.
SOLENOID
BODY _ _~ ~
ASSEMBLY
7G391
10. NOTE: Steel EPC check ball is spring loaded

under valve body separating plate (7A008).
Remove three separating plate reinforcing plate
bolts using an 8mm socket. Remove separating
plate reinforcing plate.
D8958-D
8. Push up on solenoid body assembly connector

while removing solenoid body assembly.
08961·0
SOLENOID BODY
ASSEMBLY D8959-D

ALL RIGHTS RESERVED
11. Remove valve body separating plate and two

gaskets. Discard gaskets.
EPC BLOW OFF

SPRING
70017
D8962-C
12. CAUTION: Use care not to damage rubber

check balls.
NOTE: The steel EPC check ball is a O.25-inch
diameter and is smaller than the rest.
Remove steel EPC check ball and nine rubber
check balls from transmission, using a small
screwdriver.
D904D-G

ALL RIGHTS RESERVED
13. Depress the intermediate band servo retainer and 14. CAUTION: Discard feedbolts after removal.
remove the intermediate servo piston retaining Remove three feedbolts using a 13mm socket.
ring. Remove the intermediate band servo Discard feedbolts.
retainer, intermediate band servo piston (70021),
and servo piston spring (70028).
FEED
BOLTS
(3 REC'O)
INTERMEDIATE SERVO
PISTON RETAINING RING
7381
D8964-D
INTERMEDIATE
SERVO PISTON
RETAINING RING
7381
·D8966-D
INTERMEDIATE
BAND SERVO
PISTON
70021
D8965-E

ALL RIGHTS RESERVED
Q7-01A-134 Transmission, Automatic, E40D 07-01A-134
15. CAUTION: Discard pump bolt washers after

removal. Do not reuse. IMPACT SLIDE
HAMMERS T59l-10Q-B
Rotate transmission so that converter housing is
facing up. Remove nine pump bolts using a 10mm
socket. .
PUMP BOLTS
(9 RECtO)
INSTAll PUMP PULLER

ADAPTERS T89T·70010-A
IN THESE lWO HOLES D10884-A
17. Remove oil pump gasket (7A136) and No. 1 pump

INSTALL PUMP PULLER
thrust washer. Discard oil pump gasket.
ADAPTER IN THESE 18. Remove No. 2A overdrive sun gear thrust bearing
BOLT HOLES between front oil pump assembly and overdrive
08967-8 sun gear (70063).
16. NOTE: The impact slide hammers should be at
approximately the 2 and 8 o'clock positions. NO. 2A OVERDRIVE SUN GEAR
THRUST BEARING
NOTE: No. 1 pump thrust washer and No. 2A 7E486
overdrive sun gear thrust bearing may stay with
pump.
Use two threaded holes in pump and install Pump
Puller Adapter T89T-700 10-A. Install Impact Slide
Hammer T59L-100-B into adapter and remove
front oil pump assembly. Use slide hammer type
puller only.
OIL PUMP
GASKET-7A136
D8969-E

ALL RIGHTS RESERVED
19. Lift out the coast clutch assembly. 21. Remove overdrive clutch pressure plate and
clutch pack and tag for reassembly.
OVERDRIVE CLUTCH
PRESSURE PLATE
AND CLUTCH PACK
D8973-B
20. Remove overdrive clutch pressure plate retainer
~nap ring using large screwdriver.
OVERDRIVE CLUTCH
PRESSURE PLATE
RETAINER SNAP RING
7D483
D8972-e

ALL RIGHTS RESERVED
22. CAUTION: The input shaft and overdrive

planet assembly are serviced as mating
components. Do not mix 1995 parts and
prior year service parts.
Remove overdrive ring gear and overdrive center
shaft assembly, overdrive planet and one-way
clutch and No.5 overdrive center shaft thrust
bearing assembly.
CLUTCH SPRING
FIXTURE ADAPTER
T89T-7001 0-C3 ... CLUTCH SPRING
COMPRESSOR BAR
T89T-70010-C1
OVERDRIVE RING
GEAR AND
OVERDRIVE CENTER
SHAFT ASSEMBLY
CLUTCH SPRING
FIXTURE PLATE
NO.5 OVERDRIVE T89T-70100-C2 TOOL ASSEMBLY
CENTER SHAFT VIEW A
THRUST BEARING
ASSEMBLY D8975-8
7G178
24. Remove overdrive clutch pressure plate retainer
OVERDRIVE RING snap ring with large screwdriver. Loosen spring
GEAR AND OVERDRIVE
CENTER SHAFT compressor center bolt and remove compressor
ASSEMBLY tools.
CLUTCH SPRING
COMPRESSOR
08974-0 BAR
T89T-7001 O-C1
23. Install Clutch Spring Fixture T89T-70010-C onto

intermediate / overdrive cylinder assembly.
lighten center bolt to 7 N·m (65Ib-in).
OVERDRIVE CLUTCH
PRESSURE PLATE
RETAINER SNAP RING
70483 D8976-C

ALL RIGHTS RESERVED
07-01A-137 Transmission, Automatic, E40D 07·01A·137
25. CAUTION: Do not tilt the 27. CAUTION: Do not tilt the center support in
intermediate/overdrive cylinder assembly in the case bore. Damage could result.
the case bore. Damage could result. Carefully remove center support assembly.
Remove intermediate / overdrive cylinder
assembly.
INTERMEDIATE!
OVERDRIVE
CYLINDER
ASSEMBLY
CENTER SUPPORT
ASSEMBLY
7A130
08979-0
08977·8 28. Remove No.6 center support thrust washer

(7L326).
26. Remove intermediate clutch piston return spring.
NO.6 CENTER SUPPORT
INTERMEDIATE THRUST WASHER
CLUTCH PISTON 7L326
RETURN SPRING
7B070
D8980-D
08978-8
ALL RIGHTS RESERVED
29. Remove front intermediate clutch pressure plate,

intermediate clutch pack and rear intermediate
clutch pressure plate. Tag for proper reassembly.
INTERMEDIATE
CLUTCH PRESSURE
PLATE-7B006
(FRONT)
CLUTCH REMOVER/REPLACER
T89T-70010-E 08983·8
32. Using large screwdriver, remove reverse planet

retaining ring.
INTERMEDIATE
CLUTCH PACK
08981-D
30. Remove intermediate band.
REVERSE PLANET
RETAINING RING
D8984-C
3-1. NOTE: Hooks on crossbar must be rotated to

engage notches on input shell. Refer to
illustration.
Using Clutch Remover /Replacer T89T-70010-E,
lifting upward, remove direct clutch forward
clutch and input shell.

ALL RIGHTS RESERVED
33. Remove reverse planet assembly and No. 108

and No. 11 reverse planet carrier washers. o
NO. 12 OUTPUT SHAFT HUB ----L>:~
THRUST BEARING ~
NO. 11 REVERSE PLANT 70422
THRUST WASHER - REAR
7A166
--"<
o
OUTPUT SHAFT RING GEAR,
REVERSE CLUTCH HUB AND LOW
ONE-WAY CLUTCH ASSEMBLY
D8987-E
36. Using a large screwdriver remove reverse clutch

D8985-G pressure plate retaining ring.
34. CAUTION: Use care when removing the

output shaft retaining ring. The output shaft
REVERSE CLUTCH
(7060) could fall out. Do not reuse the output PRESSURE PLATE
shaft retaining ring. RETAINING RING
Using retaining ring pliers, remove the output 70483
shaft retaining ring.
~6 ~~o
08989-0
37. CAUTION: Use care not to drop output shaft

while rotating transmission.
Rotate transmission so that transmission fluid pan
OUTPUT SHAFT rail surface is facing up.
RETAINING
RING D8986-D
35. Remove output shaft ring gear, reverse clutch

hub, low one-way clutch assembly and No. 12
output shaft hub rear thrust bearing.
ALL RIGHTS RESERVED
38. Remove reverse clutch pressure plate and clutch

pack. Tag for reassembly.
REVERSE CLUTCH
PRESSURE PLATE-7B066
CLUTCH PACK REVERSE CLUTCH
PRESSURE PLATE
RETAINING RING
70483
EXTENSION HOUSING
BOLTS (9 REQ'O)
D8991-C
41. Remove output shaft, park gear (7A233) and No.

13 output shaft thrust washer.
12 O'CLOCK
D899Q-E
39. Using Seal Remover T74P-77248-A and Impact

Slide Hammer 150T-1 OO-A remove extension
housing seal.
NO. 13 OUTPUT SHAFT

THRUST WASHER
78368 OUTPUT
SHAFT
7060
D8992-E
42. Remove five bolts using a 7 / 16-inch socket from

the output shaft hub and race.
40. Remove nine extension housing bolts using a

13mm socket. Remove wiring bracket, extension
housing (7A039) and extension housing gasket OUTPUT SHAFT HUB
(7086). AND RACE BOLTS
(5 REC'O)
D8993-C

ALL RIGHTS RESERVED
43. Remove reverse clutch return spring assembly

and output shaft hub and inner race.
OUTPUT SHAFT
HUB AND INNER RACE
-----'- 70164
REVERSE CLUTCH
RETURN SPRING o
ASSEMBLY
70406 08994·0
Dllll-1A
44. Reinstall reverse clutch pressure plate and
reverse clutch pressure plate retaining ring to 46. Remove reverse clutch pressure plate retaining
restrain the reverse clutch piston (70402) during ring, reverse clutch pressure plate and reverse
removal. clutch piston from engine rear plate (7007).
47. Remove two parking rod guide plate bolts using
13mm socket. Remove the parking rod guide
plate.
PARKING ROD
GUiDE PLATE
BOLTS (2 REa'D)
~~
REVERSE CLUTCH
PRESSURE PLATE
RETAINING RING
70483 D8995·D
45. Blow into reverse clutch feed port using

compressed air. This will blowout the reverse
clutch piston against the reverse clutch pressure D8998-C
plate.
. 1995 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
48. Remove parking pawl return spring (70070), 51. Remove inner manual valve detent lever nut using
parking pawl (7A441) and parking pawl shaft a 21 mm box wrench while holding manual control
(70071) from case. lever (7A256) with a crescent wrench.
52. Remove manual valve detent lever (7A 115) and
PARKING parking lever actuating rod (7A232) from manual
PAWL SHAFT control lever shaft (7C493).
70071
D8997·E
49. CAUTION: The Torx@ head bolt has a

thread-locking compound and should be 010680-0
removed only If the case (7005) Is being
replaced. If bolt is removed, it must be
discarded and a new one Installed. Part
If required, remove the Torx@ head screw using a Item Number Description
T40 bit and remove parking pawl abutment. 1 N800287-S36 Inner Manual Valve Detent
Lever Nut
2 7A115 Manual Valve D.etent Lever
3 N620482-S2 Outer Manual Control Lever
Nut
4 7A256 Outer Manual Control Lever
5 7A323 Parking Lever Actuating Rod
53. Remove the outer manual control lever shaft nut

using a 15mm socket while holding outer manual
control lever with crescent wrench.
54. CAUTION: Discard outer manual control lever
shaft nut. Do not reuse.
Remove outer manual control lever.
55. Remove two transmission range (TR) sensor
bolts and washers using an 8mm socket and
remove TR sensor.
56. Remove manual control lever shaft.
PARKING PAWL manual control lever bore.
ABUTMENT
7G101 Remove bolt and manual control valve detent
D89S&B lever spring (7A261).
50. NOTE: A number 53 drill bit (1/ 16-inch) may be

used as an alternate method to remove the
manual lever shaft retaining pin (78210).
Remove manual lever shaft retaining pin using
Locknut Pin Remover T78P-3504-N.

ALL RIGHTS RESERVED
DISASSEMBLY AND ASSEMBLY OF

DISASSEMBLY (Continued) SUBASSEMBLIES
58. Remove manual control lever shaft seal (7F337) Front and Rear Case Bushings
using Puller T58L-1 01-8.
NOTE: Remove and replace only one bushing at a time
while using the other bushing in the case to help align
the tool and bushing during installation.
SPECIAL SERVICE TOOL{S) REQUIRED

Rear Case Bushing Replacer T92T-77110-AH
Threaded Drawbar T77F-1176-A
I
MANUAL CONTROL
LEVER SHAFT
SEAL-7F337 D10681-C
59. NOTE: Remove case bushings only if they show

signs of excessive wear or scoring.
Inspect case bushing bores for nicks or burrs.
Remove any nicks or burrs using a fine oil stone.
60. NOTE: The short fluid inlet tube should be
removed only if it is loose or damaged.
If necessary, remove short fluid inlet tube, using
channel lock pliers.
D9006-C

ALL RIGHTS RESERVED

SUBASSEMBLIES (Continued)
1. CAUTION: Be careful not to damage the case

bore while removing th. bushing. Remove all
minor nicks or burrs in the case bore using a
fine oil stone.
Remove the rear case bushing only using Seal
Remover TOOL-1175-AC and Impact Slide
Hammer T50T-100-A as shown.
011844-8
2. Using Rear Case Bushing Replacer

REAR CASE
T92T-77110-AH, place the rear case bushing on BUSHING
the portion of the tool as shown. REPLACER
T92T-77110-AH
REAR CASE
BUSHING
REPLACER
T92T-77110-AH
REAR CASE BUSHING D14268-A
5"DRAWBAR,
NUT AND WASHER
T77F-1176-A D14267-A
3. Place the remaining portion of Rear Case Bushing

Replacer T92T-7711 O-AH and 127mm (5 inch)
Threaded Drawbar T77F-1176-A through the
front of the case into the front case bushing as
shown.

ALL RIGHTS RESERVED

4. CAUTION: Make sure the bushing and tool

are centered in the bore.
Place the portion of the tool with the rear case
bushing into the rear of the case over the
drawbar as shown. Attach washer and nut to
drawbar and handtighten.
REAR CASE
BUSHING
SEAL
REMOVER
TOOL·1175-AC
D14271-A
7. CAUTION: Front case bushing has oil

REAR CASE grooves on the bushing inner diameter.
BUSHING Locate an oil groove at 12 o'clock position in
REPLACER the case bore during bushing installation.
T92T-77110-AH
NOTE: Top of case is always 12 o'clock.
D14269-A
Using Rear Case Bushing Replacer
T92T-77110-AH, place the front case bushing on
5. Hold the drawbar with a 1/2 inch wrench, while the portion of tool as shown.
turning the nutwith another 1-1/8 inch wrench as
shown.
a. Turn the nut until the rear case bushing is fully FRONT CASE BUSHING
seated. 7025
NUT WASHER (WITH OIL GROOVE)
b. Unscrew the nut and remove all tools.
WRENCH (1-1/8")
THREADED
5"DRAWBAR
T77F-1176-A
D14272-A
8. Set portion of tool with front case bushing and

drawbar into bushing bore from the front as
shown in the following illustration. Locate on oil
REAR CASE groove in the 12 o'clock position.
BUSHING D1427D-A
6. Remove the front case bushing using Seal

Remover TOOL-1175-AC and Impact Slide
Hammer T50T-100A as shown.
ALL RIGHTS RESERVED

9. CAUTION: Make sure the bushing and tool Main Control Valve Body
are centered in the bore. 1. Clean all parts, except non-metallic check balls,
Place the remaining portion of Rear Case Bushing thoroughly -in clean solvent and blow dry with
Replacer T92T-77110-AH into the rear bushing in moisture-free compressed air.
the case as a guide. Install washer and nut hand 2. Inspect all valve and plunger bores for scores.
tight. Check all fluid passages for obstructions. Inspect
all mating surfaces for burrs and scores. If
FRONT CASE BUSHING REAR CASE damaged, replace the main control valve
7025 BUSHING body.
(WITH OIL GROOVE) REPLACER
T92T·n110-AH
3. Inspect all springs for distortion. Check all valves
and plungers for free movement in their
respective bores when dry.
4. Roll the valves on a flat surface to check for bent
condition.
12 O'CLOCK
POSITION
D14273-A
10. Hold the drawbar with a 1/2 inch wrench, while

turning the nut with another 1-1 /8 inch wrench as
shown.
a. Turn the nut until the front case bushing is fully
seated.
b. Unscrew the nut and remove all tools.
TB-3097-A
ALL RIGHTS RESERVED

Main Control Valve Bodies and Accumulator Valve Body
11 '09256·0
ALL RIGHTS RESERVED

Part Part
1 7A092 Upper Main Control Valve 38 - 1-2 Manual Transmission
Body Valve (Part of 7A 101)
2 - Manual Valve 39 - Spring (Part of 7A 101)
(Part of 7A092) 40 - Retainer (Part of 7A 10 1)
3 - Retainer (Part of 7A092) 41 7G393 Accumulator Control Body
4 - Low / Reverse Modulator 42 - Overdrive Clutch
Valve (Part of 7A092) Accumulator Regulator -
5 - Spring (Part of 7A092) Valve (Part of 7G393)
6 - Retainer (Part of 7A092) 43 - Spring (Part of 7G393)
7 7F259 3-4 Shift Valve 44 - Retainer (Part of 7G393)
(Part of 7A092) 45 - Overdrive Clutch
8 - Spring (Part of 7A092) (Part of 7G393)
9 - Plug (Part of 7A092) 46 - Outer Spring (Part of 7G393)
10 - Clip (Part of 7A092) 47 - Inner Spring (Part of 7G393)
11 - 2-3 Shift Valve 48 - Plug (Part of 7G393)
(Part of 7A092) 49 - Clip (Part of 7G393)
12 - Spring (Part of 7A092) 50 - Direct Clutch Accumulator
13 - Retainer (Part of 7A092) Regulator Valve
(Part of 7G393)
14 - Drive 2 Shift Valve
(Part of 7A092) 51 - Spring (Part of 7G393)
15 - Spring (Part of 7A092) 52 - Retainer (Part of 7G393)
16 - 1-2 Shift Valve 53 - Direct Clutch Accumulator
(Part of 7A092) Plunger (Part of 7G393)
17 - Plug (Part of 7A092) 54 - Outer Spring (Part of 7G393)
18 - Clip (Part of 7A092) 55 - Inner Spring (Part of 7G393)
19 - 4-3-2 Manual Timing Valve 56 - Plug (Part of 7G393)
20 - Spring (Part of 7A092) 58 - Intermediate Clutch
21 - Retainer (Part of 7A092) Accumulator Regulator
Valve (Part of 7G393)
22 - 4-3-2 Manual Timing Plunger
(Part of 7A092) 59 - Spring (Part of 7G393)
23 - Plug (Part of 7A092) 60 - Retainer (Part of 7G393)
24 - Clip (Part of 7A092) 61 - Intermediate Clutch
Accumulator" Plunger
25 - Coast Clutch Shift Valve
(Part of 7G393)
(Part of 7A092)
26 - Spring (Part of 7A092) 62 - Outer Spring (Part of 7G393)
27 - Retainer (Part of 7A092) 63 - Inner Spring (Part of 7G393)
28 - Solenoid Regulator Valve 64 - Plug (Part of 7G393)
29 - Spring (Part of 7A092) 66 - Line Modulator Pressure
30 - Retainer (Part of 7A092) Valve (Part of 7G393)
31 - Check Ball (Part of 7A092) 67 - Outer Spring (Part of 7G393)
32 7A008 Valve Body Separating Plate 68 - Spring and Retainer
Assembly (Part of 7G393)
33 7A101 Lower Main Control Valve
Body 69 - Line Modulator Pressure
Plunger Valve
34 - Engagement Control Valve (Part of 7G393)
(Part of 7A 101)
70 - Line Modulator Pressure
35 - Spring (Part of 7A 101) Sleeve (Part of 7G393)
36 - Plug (Part of 7A 101)
71 - Clip (Part of 7G393)
37 7G007 Valve Plug Retainer - Main Control Valve Body
72
(Part of 7A 10 1)
Bolts
(Continued)
ALL RIGHTS RESERVED
Oil Pump Assembly

Impact Slide Hammer T59L-100-B
Front Pump Seal Replacer T63L-77837-A
Pump Assembly
VIEWS
~;:o
VIEW A
9
. (~®
20 29
~ I
36
D9277-F
Part Part
1 - Pump Body (Part of 7A 103) 8 - Spring Retainer
2 - Control Body (Part of 7A 103) (Part of 7A 103)
·3 70441 Square Cut Front Oil Pump 9 - Outer Spring (Part of 7A 103)
Seal 10 Inner Spring (Part of 7A 103)
'4 7B258 Converter Hub Bushing 11 - Main Regulator Booster
5 7A248 ~Front Oil Pump Seal Valve (Part of 7A 103)
6 N805260-S Bolt and Washer Assembly 12 - Main Regulator Booster
(9 Req'd) Sleeve (Part of 7A 103)
7 - Main Regulator Valve 13 - Retainer Clip
(Part of 7A 103) (Part of 7A 103)

ALL RIGHTS RESERVED

Part Part
14 - Converter Regulator Valve 27 - Spring and Stop Assembly
(Part of 7A 103) (Part of 7H 132)
15 - Spring (Part of 7A 103) 28 - Solid Cup Plug
16 - End Plug (Part of 7A 103) (Part of 7A 103)
17 - Retainer Clip (Part of 7A 103) 29 - Front Input Shaft Bushing
(Part of 7A 103)
18 - Converter Clutch Control
Valve (Part of 7A 103) 30 - Rear Input Shaft Bushing
(Part of 7A 103)
19 - Spring (Part of 7A 103)
20 - Solid Cup Plug 31 - Bolt M8 (11 Req'd)
(Part of 7A 103)
(Part of 7A 103)
21 - Orificed Cup Plug 32 - Orificed Cup Plug
22 - Orificed Cup Plug 33 - Orificed Cup Plug
34 7L323 Front Pump Support Seal
23 - Air Bleed Check Valve
Assembly (Part of 7A 103) 35 7G402 Coast Clutch Seal
24 - Inner Gerotor Gear 36 - Inlet Tube Bore
25 - Outer Gerotor Gear A - Tighten to 24-31 N·m
(Part of 7A 103) (18-23 Lb-Ft)
26 N805802 Orifice Cup Plug B - Tighten to 24-31 N·m
(18-23 Lb-Ft)
(Continued)
Disassembly 2. Remove front pump support seal (7L323) from

1. Inspect front oil pump seal (7A248). If damaged, front of stator support.
remove with Impact Slide Hammer T59L-100-B 3. Remove two Teflon@ coast clutch seals from
and Seal Remover TOOL-1175-AC. stator support. Remove pump outer diameter
square cut front oil pump seal.
IMPACT SLIDE HAMMER

T59L-100-B
SEAL REMOVER
TOOL-1175-AC
.I
SQUARE CUT
FRONT OIL
PUMP SEAL
FRONT 7D441
OIL PUMP D11849-C
ASSEMBLY
7A103
D9056-C

ALL RIGHTS RESERVED

4. CAUTION: Use care not to damage any

machined surfaces of stator support. Part
Remove orifice cup plug and discard. Item Number Description
5. NOTE: Make sure the old rubber stop is removed

4 - Inlet Tube Bore
5 7H132 Spring and Stop Assembly
(it may have become separated from the spring (Serviced in 7H 132)
assembly). Remove spring and stop assembly.
6 - Front Input Shaft Bushing
(Part of 7A 103)
6. CAUTION: Do not reuse removed orifice cup
plug, or removed spring and stop assembly. 7 - Rear Input Shaft Bushing
(Part of 7A 103)
Clean and inspect bore, making sure bore is
clear of any debris. . 8 N805802-S 100 Orifice Cup Plug
9 7H132 Converter Drainback Spring
and Stop Assembly
7. Obtain Banding Tool D89L-7700-A or equivalent

and one 10mm bolt prior to removing pump body
bolts. This tool is needed to align the pump with
the control body assembly during reassembly.
8. NOTE: For the next two steps, refer to pump
assembly illustration.
Remove eleven bolts and separate pump control
body from pump body. Prior to removing last bolt,
support pump body.
PUMP BOLT
(11 REC'D)
CONTROL BODY
4 (PART OF 7A103)
PUMP BODY
(PART OF 7A103)
011850-8
9. CAUTION: DO NOT remove any of the cup

plugs. DO NOT remove stator support from
VIEW A
control body as this may distort the surface
D14299-A of the control body.
Apply pressure to main regulator booster sleeve
and remove retainer. Remove main regulator
Part
valve train.
10. Remove converter regulator valve assembly by
1 - Stator Support Mating
applying pressure to end plug and removing
Surface
retainer clip with small screwdriver or tweezers.
2 N805802-S 100 Orifice Cup Plug (Serviced in
7H132) . 11. Remove converter clutch shift valve assembly by
3 70014 No. 2A Overdrive Sun Gear applying pressure to end plug and removing
Thrust Bearing retainer clip with small screwdriver or tweezers.
(Continued)

ALL RIGHTS RESERVED

12. Remove gerotor gearset from pump body. 16. Inspect input shaft bushings. If bushings are worn
or scored, replace entire pump assembly.
09282-8
13. Clean all pump parts in solvent and dry with

compressed air.
14. Inspect pump gears, faces, gear teeth, pump REAR INPUT
COAST CLUTCH SEALS SHAFT BUSHING
housing and mating surfaces for damage or 7G402 (PART OF 7A103)
scoring. Replace entire pump if any part is
damaged or worn. o~
15. Inspect converter hub bushing. Replace entire STATOR
SUPPORT
pump if scored or excessively worn. (PART OF
7A103)
U
D9284-E

ALL RIGHTS RESERVED

17. Place pump gerotor gearset in pump gear pocket, 22. All depth measurements must be within
centered to pump bushing diameter. ·.0254-.0510mm (0.0015-0.0022 inch). If either
reading is out of specification, replace the front oil
pump assembly.
23. Inspect all valve and plug bores for scoring or
damage. Check all passages for obstructions.
Inspect mating surfaces for burrs and scoring.
24. Inspect all springs for distortion. When dry, make
sure all valves and plugs move freely within their
bores.
Assembly
1. Install main regulator valve assembly as shown in
control body assembly exploded view. Apply
pressure to main regulator booster sleeve and
install retainer clip. Make sure retainer clip is
properly seated.
2. Install converter clutch shift valve assembly.
D11851-8 3. Install torque converter regulator valve assembly.
4. Lightly coat the gerotor gears with transmission
18. Using depth micrometer, measure and record the fluid and install in pump housing. The dot on the
depth of inner gerotor gear face to the machined inner gerotor gear must face the control body
surface of the pump body. The inner diameter of assembly.
the inner gar should be centered over the bushing
for this step.
19. Repeat measurement for a total of three readings
in equally spaced locations on gear face.
20. Remove the inner gear and install the outer gear.
D11852-A
09282·8
21. Using depth micrometer, measure and record the

depth of the outer gerotor gear to the machined
surface of the pump body.
1995 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain ~~~y 1994

ALL RIGHTS RESERVED

5. CAUTION: Prior to pump assembly, make 7. Tighten bolts to 24-31 N·m (18-23 Ib-ft) and
sure all cup plugs are installed. remove banding tool. Make sure the outer edges
of the control body and the pump body are
Inspect mating surfaces of pump body and
completely aligned.
control body to be sure they are clean and free of
nicks and burrs. Lower the control body and 8. NOTE: Be sure seal grooves are clean and free of
stator assembly onto the pump body, aligning the burrs.
28mm round hole in the control body with the NOTE: Be sure coast clutch seals are fully
28mm hole in the pump body. seated in grooves and oriented 180 0 apart.
PUMP
BODY
(PART OF
7A103)
., .,
RIGHT WRONG
D9289·1A
Install coast clutch Teflon@ seals. Install outer

diameter seal.
REAR INPUT
COAST CLUTCH SEALS SHAFT BUSHING
7G402 (PART OF 7A103)
o~
STATOR
D9287-e SUPPORT
(PART OF
6. Loosely install eleven M8x50 bolts. Install one 7A103)
10mm bolt in the position shown and install U
Banding Tool D89L-77000-A or equivalent with
clamp by filter inlet. Align outer bolt holes and
tighten banding tool.
ALIGNMENT
BOLT (10mm)
D9284-E
9. Install front pump support seal on front of stator

support in same manner as coast clutch seals.
BANDING TOOL
D89L-71000-A
D1069G-A

ALL RIGHTS RESERVED

10. Install a new spring and stop a~embly from 13. Make sure the cup plug edges are seated just
service kit E9T-7H 132-8. . below the stator support surface that mates with
the No.2 needle bearing assembly.
010691·8
14. Using Front Pump Seal Replacer T63L-77837-A,

install front oil pump seal if removed.
VIEW A FRONT
PUMP SEAL
D14299-A
REPLACER
T63L-77837-A
Part FRONT OIL
Item Number Description PUMP
7A103
1 - Stator Support Mating
Surface
2 N805802-S10Q Orifice Cup Plug (Serviced in
7H132)
3 70014 No. 2A Overdrive Sun Gear
Thrust Bearing
4 - Inlet Tube Bore
5 7H132 Spring and Stop Assembly
(Serviced in 7H 132) PUMPO.D.
6 - Front Input Shaft Bushing SEAL GROOVE
(Part of 7A 103) D9057-c
7 - Rear Input Shaft Bushing
(Part of 7A 103) 15. Install new spring and stop assembly. Insert end
8 N805802-S100 Orifice Cup Plug with the rubber stop into the bore first.
9 7H132 Converter Orainback Spring 16. Using a small drift and mallet, install new orifice
and Stop Assembly cup plug. Make.sure the cup plug edges are
seated just below the surface on the stator
11. Insert the end with the rubber stop into the bore support that mates with the No.2 overdrive sun
first. gear thrust bearing.
12. Using a small drift and mallet, install a new cup
plug from the service kit.

ALL RIGHTS RESERVED

17. Install No. 1 pump thrust washer and No. 2A

overdrive sun gear thrust bearing into pump
stator support. Use a light film of petroleum jelly NO. 2A OVERDRIVE
to hold washer and bearing assembly in place. SUN GEAR
THRUST BEARING
7E486
D10692-C
Coast Clutch
Refer to the following disassembled view of the coast
clutch assembly for component location and
orientation.
Coast Clutch
D92&7-D
Part Part
1 7G387 Coast Clutch Cylinder 7 70483 Coast Clutch Pressure Plate
2 7A548 Coast Clutch Piston Outer Retainer Snap Ring
Seal 8 78066 Coast Clutch Pressure Plate
3 7N519 Apply Ring 9 78164 Coast Clutch Friction Plates
4 7A527 Retaining Ring 10 78070 Coast Clutch Piston Spring
5 78442 Coast Clutch Steel Plates 11 7A262 Coast Clutch Piston
6 70063 Overdrive Sun Gear 12 7A548 Coast Clutch Piston Inner
(Continued)
Seal

ALL RIGHTS RESERVED


Clutch Spring Compressor T65L-77515-A
Disassembly
1. Remove overdrive sun gear (70063) from coast
clutch cylinder.
COAST
CLUTCH
OVERDRIVE PRESSURE
SUN GEAR PLATE
70063 78066
D906O-D
4. CAUTION: Do not fully compress the return

springs.
Using Clutch Spring Compressor T65L-77515-A
remove reverse clutch return spring retaining
ring. Remove compressor tool. Discard coast
clutch return spring retaining ring.
D9058·D
2. Remove selective coast clutch pressure plate

retaining ring.
COAST CLUTCH
PRESSURE PLATE
RETAINING
RING-7D483
D9059-D
3. Remove coast clutch pressure plate and clutch

COAST CLUTCH PISTON
plates from coast clutch cylinder. Tag clutch pack RETURN SPRING
for reassembly. RETAINING RING
7A527
09061·D
1995 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain ,July 1994

ALL RIGHTS RESERVED

5. Remove coast clutch piston return spring.
D9062·C
6. Remove coast clutch piston apply ring.
8. Remove coast clutch piston outer seal from coast

clutch piston.
COAST
CLUTCH
PISTON
APPLY
RING
COAST CLUTCH
PISTON OUTER
D9063-D SEAL
7A548
D9065-C
7. Remove coast clutch piston from coast clutch
cylinder. 9. Remove coast clutch piston inner seal from coast
clutch cylinder.

ALL RIGHTS RESERVED

Assembly
NOTE: Soak all friction plates for 15 minutes in clean
equivalent.
Lightly lube all O-ring seals before installing, using
Motorcraft MERCON® Multi-Purpose Automatic
equivalent.
1. Install coast clutch piston inner seal so that lip is
facing toward bottom (down) into coast clutch
cylinder.
COAST
CLUTCH
PISTON
INNER SEAL
7A548
4. Install coast clutch piston apply ring.
COAST
D9066-B CLUTCH
PISTON
APPLY
2. Install coast clutch piston outer seal so that lip is RING
facing toward bottom (down) onto coast clutch
piston.
D9063-D
5. Install coast clutch piston return spring.
COAST CLUTCH
PISTON OUTER
SEAL
7A548
3. Install coast clutch piston into coast clutch

cylinder.
D9062-e

ALL RIGHTS RESERVED


springs.
Using Clutch Spring Compressor T65L-77515-A
OVERDRIVE
install coast clutch piston return spring retaining SUN GEAR
ring. 70063
9. Install coast clutch pressure plate retaining ring

and check stack-up clearance (in three places
120 0 apart) using feeler gauge. If not within
specification, install correct coast clutch
pressure plate retaining ring and recheck.
Specification:
1. 14-0.62mm (0.045-0.025 inch)
COAST CLUTCH PISTON Selective Snap Rings
RETURN SPRING
RETAINING RING 1.45-1.35mm (0.057-0.053 inch)
. 7A527
1.85-1.75mm (0.073-0.069 inch)
2.25-2. 15mm (0.089-0.085 inch)
09061-0
FEELER
7. Install clutch plates alternately, starting with steel GAUGE
plate and ending with coast clutch pressure plate.
COAST
CLUTCH
PRESSURE DIOI7-1A
PLATE
78066
10. Remove coast clutch pressure plate retaining ring
and clutch plates. Performing this step is
necessary to install the overdrive center shaft
D906O-D
(7A658) assembly. For further information, refer
8. Install overdrive sun gear with short end of gear to Subassemblies in this section. '
down into coast clutch cylinder.
Overdrive Ring Gear and Center Shaft

Refer to the following disassembled view of the
overdrive ring gear and center shaft for component
location and orientation.

ALL RIGHTS RESERVED

Overdrive Ring Gear and Center Shaft Assembly
D9258-F
Part
1 377155-S Retaining Ring - Large
2 377135-S Retaining Ring - Small
3 7A089 Overdrive One-Way Clutch
4 7L339 No.3 Overdrive One-Way
Clutch Washer Part
5 7B446 Planet Gear Overdrive Item Number Description
Carrier
6 7F240 No.4 Overdrive Planet 1 - Inner Race (Part of 7A089)
Thrust Bearing Assembly 2 377135-S Small Retaining Ring
7 7A153 Overdrive Ring Gear 3 - Outer Race (Part of 7A089)
8 7A658 Overdrive Center Shaft 4 - One-Way Clutch
Retaining Ring (Part of rA089)
9 7G375
No.5 Overdrive Center Shaft 5 7A153 Overdrive Ring Gear
10 7G178
Thrust Bearing Assembly
3. Push out one-way clutch and inner race.
Disassembly
1. Remove large retaining ring. "- OUTER
"- RACE
(PART OF 7A089)
~
D10695-8
D10693-C
.2. Remove overdrive one-way clutch with inner and

outer races.

ALL RIGHTS RESERVED

4. Remove inner race from one-way clutch. 6. Remove planet gear overdrive carrier from
overdrive center shaft (7A658) and overdrive ring
gear.
OVERDRIVE CENTER SHAFT

7A658
D10696-8 AND OVERDRIVE RING GEAR
7A153
5. Remove No.3 overdrive one-way clutch washer D9073-F
from front of planet gear overdrive carrier
(78446). 7. CAUTION: Use care not to damage No.4
overdrive planet thrust bearing assembly.
NO.3 OVERDRIVE Remove No.4 overdrive planet thrust bearing
OVERRUNNING assembly from rear face of planet gear overdrive
CLUTCH
WASHER carrier.
71.339
NO.4 OVERDRIVE PLANET
THRUST BEARING
ASSEMBLY
. 7F240
PLANET GEAR
OVERDRIVE
CARRIER
78446 D9074-E
09072-0

ALL RIGHTS RESERVED

8. Remove retaining ring. 2. Install overdrive center shaft to overdrive ring

gear with retaining ring.
09075-0
09075-0
9. Remove overdrive center shaft from overdrive
ring gear. 3. Install No.4 overdrive planet thrust bearing
assembly with outer lip down on rear face of
planet gear overdrive carrier.
OVERDRIVE
CENTER SHAFT NO.4 OVERDRIVE PLANET
7A658 THRUST BEARING
ASSEMBLY
7F240
OVERDRIVE
RING GEAR
7A153
D10697-e
D9076-E
Assembly
1. Install overdrive center shaft into overdrive ring
gear.

ALL RIGHTS RESERVED

4. CAUTION: The input shaft (7017) and 7. NOTE: Inner rag undercut must face toward small
overdrive planet assembly are serviced as retaining ring.
mating components. Do not mix 1995 parts Install inner race into one-way clutch assembly.
and prior year service parts.
NOTE: Different vehicle applications will have
different planet assemblies. Refer to master parts INNER
catalog for correct usage. RACE
(PART OF
Install planet gear overdrive carrier into overdrive 7A089)
center shaft and overdrive ring gear assembly.
OUTER RACE
(PART OF 7A089)
010699-8
8. NOTE: Inner race must rotate counterclockwise.

Install overdrive one-way clutch into overdrive
ring gear with small retaining ring facing upwards.
OVERDRIVE CENTER SHAFT

7A658
AND OVERDRIVE RING GEAR
7A153
D9073-F
5. Install No.3 overdrive one-way clutch washer on

front of carrier.
NO.3 OVERDRIVE
OVERRUNNING
CLUTCH
WASHER
7L339
D10694-C
Part
1 - Inner Race (Part of 7A089)
2 377135-S Small Retaining Ring
3 - Outer Race (Part of 7A089)
4 - One-Way Clutch
(Part of 7A089)
09072-0
5 7A153 Overdrive Ring Gear
6. Install retaining ring and plastic cage into outer
race.

Y4t,., ALL RIGHTS RESERVED
07-01A-165 Transmission, Automatic, E40D .07-01A-165

9. Install large retaining ring. Intermediate/ Overdrive Cylinder Assembly

Refer to the following disassembled view of the
intermediate / overdrive cylinder assembly for
component location and orientation.
LARGE
RETAINING
RING
D10'7OO-C
10. NOTE: Inner bearing race lip must face up.
Install No.5 overdrive center shaft thrust bearing
assembly onto overdrive center shaft. Hold in
place with a light film of petroleum jelly.
NO.5 OVERDRIVE
CENTER SHAFT
THRUST BEARING
ASSEMBLY
7G178
D10701-e
1995 F-150, F-250, F-350, Bronco, F-Super Duty P.owertrain, Drivetrain July __4

ALL RIGHTS RESERVED

Intermediate / Overdrive Cylinder Assembly
D9259-F
Part Part
1 70483 Overdrive Clutch Pressure 10 70483 Intermediate / Overdrive
Plate Retaining Snap Ring Cylinder Retaining Ring
2 78066 Overdrive Clutch Pressure 11 7G384 Intermediate / Overdrive
Plate Cylinder
3 78164 Overdrive Clutch Internal 12 N805310-S 10 1 Bolt, M10-1.5 x 24mm
Spline Plates - Friction Overdrive Cylinder Fluid
4 78442 Overdrive Clutch External Feed (1 Req'd)
Spline Plates - Steel 13 7F225 Intermediate Clutch Piston
5 7A527 Overdrive Clutch Piston' Inner Seal
Return Spring Retainer 14 7E005 Intermediate Clutch Piston
6 78070 Overdrive Clutch Piston 15 7F224 Intermediate Clutch Piston
Return Spring Outer Seal
7 7A262 Overdrive Clutch Piston 16 78070 Intermediate Clutch Piston
Outer Seal Return Spring
8 7A548 Overdrive Clutch Piston 17 7A130 Center Support Assem bly
Outer Seal 18 N805311-S101 Center Support Fluid Feed
9 7F225 Overdrive Clutch Piston Inner Bolt, M12-1.75 x 31mm
Seal (2 Req'd)
(Continued) 19 7L326 Center Support Thrust
Washer (No.6)
(Continued)

ALL RIGHTS RESERVED

Part Part
20 70025 Direct Clutch Cast Iron Seal 24 78066 Intermediate Clutch
Rings Pressure Plate - Rear
21 78066 Intermediate Clutch A - Tighten to 8-14 N·m
Pressure Plate - Front (6-10 Lb-Ft)
22 78164 Intermediate Clutch Internal 8 - Tighten to 11-16 N·m
Spline Plates - Friction (8-12 Lb-Ft)
23 78442 Intermediate Clutch External
Spline Plates - Steel
(Continued)
SPECIAL SERVICE TOOL(S) REQUIRED 2. Remove overdrive clutch piston return spring
retainer.
Clutch Spring Compressor Plate T89T-700 10-C2
(Part of
T89T-70010-C)
Clutch Spring Compressor Bar T88C-77000-AH2
(Part of
T88T-77000-AH)
Clutch Spring Compressor Plate T89T-70010-F
O-Ring Tool T71 P-19703-C
Disassembly
1. Using Clutch Spring Compressor Plate
T89T-700 1O-C2 (Part of T89T-700 10-C), Clutch
Spring Compressor Bar T88C-77000-AH2 (Part OVERDRIVE
of T88C-77000-AH) and Clutch Spring CLUTCH PISTON
Compressor Plate T89T-70010-F, compress the RETURN SPRING
overdrive clutch piston return spring. RETAINER
7A527
O9079·D
CLUTCH SPRING INTERMEDIATE!
COMPRESSOR PLATE OVERDRIVE CYLINDER 3. Remove compressor tool assembly.
T89T-70010-F 7G384 4. Remove overdrive clutch piston return spring.
OVERDRIVE
CLUTCH .
PISTON
RETURN
SPRING
78070
CLUTCH SPRING
CLUTCH SPRING COMPRESSOR BAR
FIXTURE T88C-77000-AH2
T89T-700 1O-C2 (PART OF T88C-77000-AH)
(PART OF T89T-7081 O-C)
D9078-C D9080-C

ALL RIGHTS RESERVED

5. Remove overdrive clutch piston. 8. Remove intermediate clutch piston inner seal
(7F225) from cylinder bore, using O-Ring Tool
T71 P-19703-C.
INTERMEDIATE!
OVERDRIVE
CYLINDER
7G384
INTERMEDIATE
CLUTCH PISTON
INNER SEAL
6. Remove overdrive clutch piston outer seal and 7F225 D9084-D
overdrive clutch piston inner seal, using O-Ring
Tool T71P-19703-C. 9. Remove intermediate clutch piston outer seal
(7F224) from intermediate clutch piston.
INTERMEDIATE
CLUTCH PISTON
7E005
OVERDRIVE
CLUTCH PISTON
OUTER SEAL INTERMEDIATE
7A548 CLUTCH PISTON
OUTER SEAL O-RING TOOL
D9082-e 7F224 T71 P-19703-C
D9085-C
7. Remove intermediate clutch piston (7E005).
INTERMEDIATE
CLUTCH PISTON
OUTER SEAL
7F224
D9083-D
.<" ...
1995 F~150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain July 1994

ALL RIGHTS RESERVED

Assembly
1. NOTE: Prior to reassembly, inspect check ball,
cup plugs and feedbolt threads for contamination
or damage. Clean or replace as necessary. INTERMEDIATE
CLUTCH PISTON
Install intermediate clutch piston outer seal onto OUTER SEAL
intermediate clutch piston with lip seal facing 7F224
down toward cylinder.
INTERMEDIATE
CLUTCH PISTON
OUTER SEAL
7F224
D9083-D
4. Install overdrive clutch piston outer seal and
overdrive clutch piston inner seal with lip seal
facing down towards cylinder.
OVERDRIVE CLUTCH
PISTON OUTER SEAL
7A548
D9083-D
2. Install intermediate clutch piston inner seal into
cylinder bore with lip seal facing down toward
cylinder.
OVERDRIVE
CLUTCH PISTON
INNER SEAL
7F225 D10703-C
5. NOTE: Piston should rotate freely in cylinder

Install overdrive clutch piston.
3. NOTE: Piston should rotate freely in cylinder.

Install intermediate clutch piston.
ALL RIGHTS RESERVED

6. NOTE: Outerdrive clutch piston return spring

must be installed with fingers facing up.
Install overdrive clutch piston return spring.
OVERDRIVE
CLUTCH
PISTON
RETURN
SPRING
78070
OVERDRIVE
CLUTCH PISTON
RETURN SPRING
RETAINER
7A527
D9079-D
9. Remove tool assembly.
7. Using Clutch Spring Compressor Plate Center Support

T89T-700 10-F, Clutch Spring Compressor Bar
T88C-77000:AH2 and Clutch Spring Pressure Disassembly
Plate T89T-70010-C2, compress return spring. 1. Remove two direct clutch cast iron seal rings and
No.6 center support thrust washer (7L326).
CLUTCH SPRING INTERMEDIATE!

COMPRESSOR PLATE OVERDRIVE CYLINDER DIRECT CLUTCH CENTER
T89T-70010-F 7G384 CAST IRON SUPPORT
SEAL RINGS ASSEMBLY
70025 7A130
NO. BCENTER
SUPPORT
THRUST
WASHER
7L326
CLUTCH SPRING
CLUTCH SPRING COMPRESSOR BAR
FIXTURE TasC-77000-AH2 2. Inspect No.6 center support thrust washer,
T89T-7001 Q-C2 (PART OF T88C-7700Q-AH)
(PART OF T89T-7081 O-C) center support seal ring grooves, hub inner and
D9078-C outer diameters and feedbolt threads for
contamination or damage. Clean or replace as
8. Install overdrive clutch piston return spring necessary.
retainer. Make sure retainer is fully seated.
ALL RIGHTS RESERVED
07-01A-171 Transmission, Automatic, E40D 07·01A·171

3. Inspect ball bearing inside center support for

damage. Service as required.
BALL BEARING
D14300-A
Assembly 3. Remove forward hub from forward ring gear

(70392).
1. Install No.6 center support thrust washer using a
light film of petroleum jelly to hold in place.
2. Install two direct clutch cast iron seal rings. FORWARD
HUB
78067
FORWARD
RING GEAR
Forward Hub and Ring Gear 70392
Disassembly
1. Remove No.8 forward clutch hub thrust washer
from front face of hub.
NO. Be FORWARD CLUTCH HUB

THRUST WASHER
70090
D9089-B
Assembly
1. Install forward hub into forward ring gear.
FORWARD
HUB
78067 -.,.~~
D9087-e
FORWARD
2. Remove forward hub retaining ring using RING GEAR
screwdriver. 70392
D9089-B
ALL RIGHTS RESERVED

2. NOTE: Make sure forward hub retaining ring is 3. Install No. 8e forward clutch hub thrust washer
fully seated in ring groove. on the hub, using petroleum jelly.
Install forward hub retaining ring.
Intermediate Brake Drum

Refer to the direct clutch disassembly and assembly
procedure in this section.
Direct Clutch
Refer to the following disassembled view of the direct
clutch for component location and orientation.
ALL RIGHTS RESERVED

Direct Clutch
Part Part
1, - Intermediate One-Way 7 7A262 Direct Clutch Piston
Clutch Outer Race 8 7F235 Direct Clutch Return Spring
(Part of 7A089) Assembly
2 - Intermediate One-Way 9 7C122 .Direct Clutch Return Spring
Clutch Inner Race Retaining Ring
(Part of 7A089) 10 7C096 Intermediate Brake Drum
3 7G401 Intermediate One-Way Thrust Washer (No. 8A)
Clutch Thrust Washer (No.7) 11 78164 Direct Clutch Internal Spline
4 70044 Intermediate Brake Drum Plates - Friction
5 7A548 Direct Clutch Piston Inner 12 7B442 Direct Clutch External Spline
Seal Plates - Steel
6 7A548 ;
Direct Clutch Piston Outer 13 78066 Direct Clutch Pressure Plate
Seal 14 377126-S Direct Clutch Pressure Plate
(Continued) Retaining Ring (Selective)

1995 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain Ju1Y<.1994

ALL RIGHTS RESERVED

Disassembly 4. Remove No. 7 intermediate one-way clutch thrust

1. Remove intermediate one-way clutch outer race. washer from rear face of intermediate brake
drum.
NO. 7 INTERMEDIATE
ONE-WAY CLUTCH
THRUST WASHER
7G401
INTERMEDIATE
ONE-WAY CLUTCH
OUTER RACE
(PART OF 7A089)
09091-0
D9094-E
2. Remove intermediate one-way clutch inner race.
5. Remove No. 8A intermediate brake drum thrust
washer from front face of intermediate brake
TOPENO drum.
CAP
(PART OF 7A089)
INTERMEDIATE
ONE-WAY
CLUTCH
INNER RACE
(PART OF 7AOe9)
NO. 8A INTERMEDIATE
BRAKE DRUM
D10704-C THRUST WASHER
7C096
3. Remove bottom end cap. INTERMEDIATE
BRAKE DRUM-70044 D9095-F
D9093-B

ALL RIGHTS RESERVED

6. Remove direct clutch pressure plate retaining ring

using screwdriver.
9. Remove direct clutch return spring assembly.

D9096-D
7. Remove direct clutch pressure plate and clutch
pack. Tag for reassembly.
DIRECT CLUTCH
PRESSURE
PLATE
78066
DIRECT CLUTCH
RETURN SPRING
ASSEMBLY
7F235
PROTRUSION
10. Remove direct clutch piston from intermediate

CLUTCH brake drum.
PACK
D9097-F
springs.
Install Clutch Spring Compressor T65L-77515-A
and remove direct clutch return spring retaining
ring. Remove compressor tool.
INTERMEDIATE
BRAKE DRUM
70044
D91~D

ALL RIGHTS RESERVED

11. Remove inner and outer direct clutch piston seals

from intermediate brake drum using a-Ring Tool
T71P-19703-C.
O-RING TOOL DIRECT CLUTCH

T71 P-19703-e PISTON
OUTER SEAL
7A548
09102-e
3. Inspect direct clutch piston check ball for
freedom of movement and proper seating. Clean
with solvent if necessary. Replace direct clutch
piston if damaged.
4. NOTE: Piston should rotate freely in drum.
Install direct clutch piston into intermediate brake
drum.
09101-e
Assembly
1. Install direct clutch piston inner seal into
intermediate brake drum with seal lip facing
down.
DIRECT
CLUTCH PISTON
INNER SEAL
7A548
INTERMEDIATE
BRAKE DRUM
70044
09100-0
09103-C
2. Install direct clutch piston outer seal into
intermediate brake drum with seal lip facing
down.

ALL RIGHTS RESERVED

5. NOTE: Make sure protrusions on spring retainer DIRECT CLUTCH

are properly engaged with lugs on direct clutch PRESSURE
piston. PLATE
Install direct clutch return spring assembly. 78066
DIRECT CLUTCH CLUTCH

RETURN SPRING PACK
ASSEMBLY D9097-F
7F235
8. Install selective retaining ring. Check stack-up in
three positions 120 0 apart using feeler gauge. If
not within specification, install correct selective
PROTRUSION retaining ring and recheck.
Specification:
6. Compress direct clutch return spring assembly 1. 14-2.06mm (0.045-0.081 inch)
using Clutch Spring Compressor T65L-77515-A.
Install direct clutch return spring retaining ring, Selective Retaining Rings
then remove compressor tool. 1.42-1.54mm (0.056-0.060 inch)
1.65-1.75mm (0.065-0.069 inch)
1.88-1.98mm (0.074-0.078 inch)
2.11-2.21mm (0.083-0.087 inch)
FEELER
GAUGE
7. NOTE: Soak the clutch plates with clean

equivalent for fifteen minutes.
Install three, four or five plate clutch pack
(depending on model), starting with steel plate
and alternating with friction plates. Install direct
clutch pressure plate.

ALL RIGHTS RESERVED

9. Install No. 7 intermediate one-way clutch large

thrust washer on face of intermediate brake TOP END
CAP
drum. (PART OF 7A089)
NO. 7 INTERMEDIATE INTERMEDIATE

ONE-WAY CLUTCH ONE-WAY
THRUST WASHER CLUTCH
7G401 INNER RACE
(PART OF 7A089)
D10704-C
12. NOTE: Shoulder on intermediate one-way clutch

outer race should be up.
D9094-E Install intermediate one-way clutch outer race and
check that it turns counterclockwise.
10. NOTE: Top and bottom end caps are identical.
Install bottom end cap.
INTERMEDIATE ONE-WAY CLUTCH
OUTER RACE
(PART OF 7A089)
D10705-8
11. NOTE: Lip on the intermediate one-way clutch

inner race should be up.
D10706-C
Install intermediate one-way clutch inner race.
Install top end cap.

ALL RIGHTS RESERVED

13. Using a light film of petroleum jelly, install No. SA

intermediate brake drum thrust washer on face of
intermediate brake drum.
NO. SA INTERMEDIATE
BRAKE DRUM
THRUST WASHER
7C096
INTERMEDIATE
BRAKE DRUM-7D044 D9095-F
Forward Clutch Refer to the following disassembled view of the

forward clutch assembly for component location and
SPECIAL SERVICE TOOL(S) REQUIRED orientation.
Lip Seal Protector T77L-77548-A
Forward Clutch

ALL RIGHTS RESERVED

Part Part
1 70019 Forward Clutch Cylinder 10 78066 Forward Clutch Pressure
Seals Plate - Bottom
2 7F374 Forward Clutch Needle 11 7B070 Forward Clutch Pressure
Bearing Assembly (No. 8B) Spring
3 7A360 Forward Clutch Cylinder 12 7B442 Forward Clutch External
4 7A548 Forward Clutch Piston, Inner Spline, Plate - Steel
Seal 13 7B164 Forward Clutch Internal
5 7A548 Forward Clutch Piston, Outer Spline Plates - Friction
Seal 14 7B066 Forward Clutch Pressure
6 7A262 Forward Clutch Piston Plate - Top
7 70256 Forward Clutch Piston Apply 15 377127-S Forward Clutch Pressure
Ring Plate Retaining Ring
(Selective Fit)
8 7B070 Forward Clutch Piston
Return Spring 16 70234 Forward Clutch Thrust
Bearing (No. 9A)
9 377127-S Forward Clutch Piston
Return Spring Retaining Ring
(Continued)
Disassembly
NO. 88 FORWARD CLUTCH
1. Remove the No. 9A forward clutch thrust bearing NEEDLE BEARING
from the inner face of the forward clutch cylinder. 7F374
O9275-D
3. Remove both forward clutch cylinder seals from
grooves.
09105-0
2. Remove No. 88 forward clutch needle bearing
assembly.

ALL RIGHTS RESERVED

4. Remove forward clutch pressure plate retaining

ring.
FORWARD
CLUTCH FORWARD CLUTCH
PRESSURE PISTON RETURN
IIJ."..~~-"--- PLATE
RETAINING SPRING
RING 78070
FORWARD CLUTCH
PISTON RETURN
SPRING RETAINING
RING
09109-0
8. Remove forward clutch piston return spring.
D9107·C
5. Remove top forward clutch pressure plate. FORWARD CLUTCH
PISTON RETURN SPRING
6. Remove three or four plate clutch pack, 78070
(depending on vehicle application), forward clutch
pressure spring and plate. Tag for reassembly.
TOP
FORWARD
CLUTCH
PRESSURE
PLATE
78066
FORWARD CLUTCH
PISTON APPLY
RING
70256
D911G-C
9. Remove forward clutch piston apply ring from
forward clutch piston groove.
FORWARD CLUTCH
PRESSURE SPRING BQlTOM FORWARD
7E085 CLUTCH PRESSURE
PLATE
78066
D9108-E
7. Remove forward clutch piston return spring
retaining ring.
FORWARD CLUTCH
PISTON APPLY
RING
70256
D9111·C

ALL RIGHTS RESERVED

10. Remove forward clutch piston from cylinder using

compressed air. . O-RING TOOL
FORWARD CLUTCH T71 P-19703-C
PISTON INNER SEAL
7A548
APPLY AIR HERE TO REMOVE
FORWARD CLUTCH PISTON
D9114-C
Assembly
1. Install forward clutch piston inner seal front clutch
cylinder.
FORWARD
D10707-e CLUTCH
PISTON
11. Remove outer forward clutch piston seal from INNER
SEAL
forward clutch piston. 7A548
FORWARD CLUTCH
PISTON OUTER SEAL
7A548
(LIP UP)
D9115-C
2. Inspect forward clutch piston check ball for
freedom of movement and proper seating.
09113-D
Replace forward clutch piston assembly if
12. Remove forward clutch piston inner seal from the necessary. Clean with a suitable solvent if
forward clutch cylinder using O-Ring Tool necessary.
171 P-19703-C.
CHECK BALL
(PART OF 7A262) D10708-8

ALL RIGHTS RESERVED

3. Install forward clutch piston outer seal on forward 6. CAUTION: Forward clutch piston return
clutch piston with lip facing up as shown. spring and forward clutch piston apply ring
must be pos,tioned so that both ends of the
FORWARD CLUTCH forward clutch piston apply ring are visible in
PISTON OUTER SEAL the notch between the fingers of the forward
7A548 ' clutch pi.ton return spring to ensure
(LIP UP) durability of the forward clutch piston return
spring.
Install forward clutch piston return spring with the
spring fingers 'against the forward clutch piston
apply ring.
FORWARD CLUTCH
PISTON RETURN SPRING
78070
09113-0
4. Install forward clutch piston into forward clutch

cylinder using Lip Seal Protector T77L-77548-A.
FORWARD
CLUTCH LIP SEAL
PISTON PROTECTOR
7A262 T77L-77548-A
FORWARD CLUTCH
PISTON APPLY
RING
70256
D911O-C
FORWARD
FORWARDCL~
PISTON RETURN / / APPLY RING
CLUTCH SPRING OPENING
CYLINDER 78070
7A360
D9116-C
5. Install steel forward clutch piston apply ring into
forward clutch piston groove.
D10709-C
FORWARD CLUTCH
PISTON APPLY
RING
70256
D9111-C

ALL RIGHTS RESERVED

7. Install forward clutch piston return retaining ring. 12. Install forward clutch pressure plate retaining
Verify proper seating in groove. ring.
13. Using feeler gauge, check stack-up clearance in
three positions 120 0 apart. If not within
specification install correct retaining ring and
recheck.
Stack Up Clearance Specification:
FORWARD CLUTCH
PISTON RETURN 1.40-0.76mm (0.055-0.030 inch)
SPRING Selective Retaining Ring Thickness:
78070
1.42-1.52mm (0.056-0.060 inch)
1.88-1.98mm (0.074-0.078 inch)
2.34-2.44mm (0.092-0.096 inch)
2. 79-2.90mm (0.110-0.114 inch)
3.25-3.35mm (0.128-0.132 inch)
FORWARD CLUTCH
PISTON RETURN
SPRING RETAINING
RING
09109-0
8. Install bottom forward clutch pressure plate
(beveled face down).
9. Install forward clutch pressure spring.
10. NOTE: Soak the clutch plates with clean
Transmission Fluid XT-2-QOX or MERCON@ FEELER
equivalent. GAUGE
Install three steel plates and three friction plates, D7877·1A
or four steel plates and four friction plates 14. Using a light film of petroleum jelly, install No. 88
(depending on transmission model). Alternate forward clutch needle bearing assembly with
steel and friction starting with a steel plate. large 1.0. radius facing inward.
11. Install top forward clutch pressure plate.
TOP NEEDLE BEARING
FORWARD 7F374
CLUTCH
PRESSURE
PLATE
78066
09275-D
FORWARD CLUTCH
PRESSURE SPRING BOnOM FORWARD
7E085 CLUTCH PRESSURE
PLATE
78066
D9108-E

ALL RIGHTS RESERVED

15. NOTE: Stagger the scarf cuts on seals 180 0

apart when installed.
Install forward clutch cylinder seals in grooves.
D14301-A
Forward Planet Assembly

Disassembly
D9106·C
1. Remove No. 98 forward clutch thrust bearing
16. Using a light film of petroleum jelly, install No. 9A from forward planet assembly.
forward clutch thrust bearing on inner face of
forward clutch cylinder, with large 0.0. radius FORWARD
facing inward. PLANET
ASSEMBLY
7A398
NO. 9B FORWARD CLUTCH

THRUST BEARING
7D234 09117.E
2. Remove No. 10 forward planet assembly thrust
washer from front side of forward planet
assembly.
Output Shaft
The output shaft (7060) cannot be disassembled. The
output shaft must be replaced, if damaged.
Inspect the output shaft for wear. Make sure the cup NO. 10A FORWARD
plug orifice is clean and free of debris. Service as PLANET ASSEMBLY
required. THRUST WASHER
7A166
09118-D

ALL RIGHTS RESERVED

Assembly RETAINING
1. NOTE: Thrust washer tabs go into forward planet RING
assembly slots.
Place No. 10 forward assembly planet thrust
washer on front side of forward planet assembly,
using petroleum jelly to hold in place.
NO. 10A FORWARD

PLANET ASSEMBLY
THRUST WASHER
7A166
INPUT
SHEll
70064
D9119·D
2. Remove input shell thrust washer (70066) from

09118-0 input shell.
2. NOTE: Install notched inner race facing outward
and large 0.0. radius facing inward.
Install No. 98 forward clutch thrust bearing on
inner face of forward planet assembly.
FORWARD
PLANET
ASSEMBLY
7A398
INPUT
~--SHElL
70064
09120-8

THRUST BEARING
70234 D9117·E
Input Shell
1. Remove and discard retaining ring from
forward / reverse sun gear using retaining ring
pliers.

ALL RIGHTS RESERVED

3. Remove forward / reverse sun gear from input

shell.
INPUT
..---SHELL
70064
09120-8
3. CAUTION: Use care not to over-extend

09121-8 retaining ring.
Install new retaining ring onto forward / reverse
Assembly sun gear using retaining ring pliers.
1. Install forward / reverse sun gear, so that lube
hole in gear is between stand-off pads on input RETAINING
shell. RING
INPUT
09121-8 SHELL
70064
2. Install input shell thrust washer onto D9119-D
forward / reverse sun gear..
1995 F-150. F-250, F-350. Bronco, F-Super Duty Powertrain. Drivetrain July 1994

ALL RIGHTS RESERVED

Reverse Planet Assembly 2. Install No. 11 rear reverse planet thrust washer
with tabs positioned into slots on planet carrier.
Disassembly Hold in place using petroleum jelly.
1. Remove rear reverse planet thrust washer.
NO.1 REVERSE PLANET
NO.1 REVERSE PLANET THRUST WASHER
THRUST WASHER 7A166
7A166
D9122·E
D9122·E
2. Remove No. 108 front reverse planet thrust
washer.
Reverse Clutch
Assembly
1. Install No. 108 front thrust washer with tabs
positioned in slots on reverse planet assembly. The reverse clutch is removed and installed during
Hold in place using petroleum jelly. disassembly and assembly of the transmission. Refer
to the procedure in this section.
NO. 1DB REVERSE PLANET

THRUST WASHER
7A166
Extension Housing
The extension housing (7A039) is disassembled and
assembled during the disassembly and assembly of
the transmission. Refer to the procedure in this
section.
Low One-Way Clutch

REVERSE
PLANET Refer to the following disassembled view of the
ASSEMBLY low / reverse clutch assembly for component location
70066 D9123-E and orientation.

ALL RIGHTS RESERVED

Low One-Way Clutch 2. Remove if necessary low, one-way clutch

assembly from reverse clutch hub.
Rotate low one-way clutch assembly
counterclockwise and remove from the rear of the
reverse clutch hub.
REMOVE
t!!f!!!I
012806-8
Part
1 387031-S Output Shaft Retaining Ring
2 7A153 Output Shaft Ring Gear
FRONT OF
3 70164 Output Shaft Hub and Race CLUTCH HUB 012816-8
5 78067 Reverse Clutch Hub
6 7A089 Low One-Way Clutch
Assembly
7 70422 Output Shaft Hub Thrust
Washer (No. 12)
8 70406 Reverse Clutch Return
Spring Assembly
9 70404 Reverse Clutch Piston Inner
Seal
10 70403 Reverse Clutch Piston Outer
Seal
11 70402 Reverse Clutch Piston
Disassembly
1. Remove output shaft ring gear and No. 12 output
shaft hub thrust washer (70422) from reverse
clutch hub.
OUTPUT SHAFT
RING GEAR NO. 12 OUTPUT SHAFT
7A153 HUB THRUST
WASHER
7D422
D9124-E

ALL RIGHTS RESERVED

Assembly
1. NOTE: Check reverse clutch hub thrust surfaces
for scores and reverse clutch hub splines for
wear. Replace all worn parts.
NOTE: Inspect outer and inner low-reverse
one-way clutch race for scores or damaged
surface areas where rollers contact races.
Inspect rollers and springs for excessive wear or
damage. Inspect spring and cage.
Install the low one-way clutch assembly through
the rear of the reverse clutch hub, refer to the
illustration for component orientation and
direction of assembly. Seat low one-way clutch REVERSE
assembly carefully into reverse clutch hub, and CLUTCH
PISTON
rotate clockwise to seat bearings properly and 70402
lock tabs in place against the hub.
2. Remove reverse clutch piston inner seal.

DIRECTION OF
ASSEMBLY
~
LOW-REVERSE
ONE-WAY CLUTCH
ASSEMBLY
7A089
(ROTATE CLOCKWISE
REVERSE TO FULLY SEAT)
CLUTCH HUB FRONT OF
7B067 CLUTCH HUB
REVERSE CLUTCH REVERSE CLUTCH

D12818-B PISTON PISTON INNER SEAL
70402 70404
D9128-C
Reverse Clutch Piston Assembly
Disassembly 1. Install reverse clutch piston inner seal and
reverse clutch piston outer seal.
1. Remove reverse clutch piston outer seal
(70403).
Torque Converter Checks

Torque Converter Leakage Check
If welds on the torque converter (7902) indicate
leakage, remove the torque converter and make the
following check.
Assemble Rotunda Leak Test Kit 021-0054A or
equivalent to the torque converter. Test the torque
converter for leaks, following the directions supplied
with the kit.

ALL RIGHTS RESERVED

SUBASS~MBLIES (Continued)
Rotunda Leak Test Kit 021-0054A 4. If the clutch fails to lock up and hold a 13 N·m (10
Ib-ft) torque, replace the torque converter unit.
Dl289-1A
One-Way Clutch Check

Converter Clutch Holding Tool T77L-7902-R
Converter Clutch Torquing Tool T76L-7902-C
1. Insert the Converter Clutch Holding Tool

T77L-7902-R in one of the grooves in the stator
thrust washer.
T77L-7902-R
CONVERTER
CLUTCH
~
===========:;;;;;;;;iiiII
J SPLINED INTO
STATOR CLUTCH
INNER RACE
CONVERTER CLUTCH
TORQUING TOOL
T78L-7902-C
HOLDING mOL
CONVERTER CLUTCH D12558-A
TORQUING TOOL
T78L-7902-C End Play Check
D2877.J
2. Insert Converter Clutch Torquing Tool
T76L-7902-C in converter pump drive hub to Description Tool Number
engage one-way clutch inner race. End Play Checking Tool T80L-7902-A
3. Attach a toque wrench to the one-way clutch
1. Insert End Play Checking Tool T80L-7902-A into
tightening tool. With the one-way clutch holding
the converter pump drive hub until it bottoms.
tool held stationary, turn the torque wrench
counterclockwise. The converter one-way clutch
should lock up and hold a 13 N·m (10 Ib-ft) force.
The converter one-way clutch should rotate
freely in a clockwise direction until torquing tool
contacts the holding tool. Try the clutch for lock
up and hold in at least five different locations
around the converter.

ALL RIGHTS RESERVED

2. Expand the sleeve in the turbine spline by 5. Loosen the threaded inner post to free the tool,
tightening the threaded inner post until the tool is and then remove the tool from the converter.
securely locked into the spline.
DIAL INDICATOR
THREADED END PLAY CHECKING TOOL WITH BRACKETRY
INNER POST T80L-7902-A TOOL-4201-C
INSTALLED INTO CONVERTER END PLAY
CHECKING TOOL
T80L-7902-A
D9Z73-C
3. NOTE: Dial Indicator must be between ridges in

next step.
Attach Dial Indicator with Bracketry D5723-E
TOOL-4201-C to the tool. Position the indicator
button ,on the torque converter housing as shown
in the illustration and set the dial face at 0 (zero).
Refer to the following chart for specification.
4. Lift the tool upward as far as it will go and note
the indicator reading. The indicator reading is the
total end play which the turbine and stator share.
Replace the converter unit if the total end play
exceeds the limits. End play specifications are
listed below.
TORQUE CONVERTER END-PLAY (E40D)
New or Rebuilt Torque Converter U.ed Torque Converter
Engine mm Inch mm Inch
Gas .35-.96 .014-.038 1.8Max. .071 Max.
7.3L 01 Diesel .60-1.21 .024-.048 2.0 Max. .079 Max.
NOTE: If the torque converter is replaced. be aware that the torque converter is model dependant.
Stator to Impeller Interference Check (Gas 2. NOTE: Torque converter must be positioned on
Engine Applications Only) top of stator as shown in the illustration to
properly perform this check.
1. NOTE: Stator support may remain in pump
assembly during this test. Mount a converter on the stator support with the
splines on the one-way clutch inner race engaging
Position the stator support on a bench with the
the mating splines of the stator support.
spline end of the shaft pointing up.
3. Hold the stator support stationary and try to
rotate the torque converter counterclockwise.
The torque converter should rotate freely without
any signs of interference or scraping within the
torque converter.

ALL RIGHTS RESERVED

4. If there is an indication of scraping, the trailing

edges of the stator blades may be interfering with
the leading edges of the impeller blades. In such
cases, replace the torque converter.
TORQUE
CONVERTER
7902
09271·0
Stator to Turbine Interference Check (Gas 4. Hold the stator shaft stationary and attempt to
Engine Applications Only) rotate the turbine with the input shaft. The turbine
and lock-up clutch assemblies should rotate in
1. NOTE: Stator support may remain in pump both directions, not exceeding maximum torque
assembly during this test. of 9.5 N·m (7 Ib-ft), without any signs of metallic
Position the torque converter on the bench stud interference or scraping noise.
side down. 5. If interference exists, the stator front thrust
2. Install a stator support to engage the mating washer may be worn, allowing the stator to hit
splines of the stator support shaft. the turbine. In such cases, the torque converter
3. Install the input shaft (7017), engaging the splines must be replaced.
with the turbine hub. Check the converter crankshaft pilot for nicks or
damaged surfaces that could cause interference
when installing the transmission to the engine.
Check the converter impeller hub for nicks or
sharp edges that would damage the pump seal.
ASSEMBLY
Transmission

Oil Filter Tube Installer T89T-7001 O-G
Clutch Remover / Replacer Te9T-7001 O-E
Clutch Spring Fixture T89T-7001 O-C
Aligning Pin T89T·7001 O-B
Shift Lever Seat Replacer T74P-77498-A
Transmission Range (TR) Sensor T92P-7010-AH
Alignment Tool (MLPS Alignment Tool)
1995 F-150, F-250, F-350, Bronco, F-Super Duty P·owertrain, Drivetrain July 1994
ALL RIGHTS RESERVED
ASSEMBLY (Continued)
NOTE: Soak all friction clutch plates in clean

SHORT FLUID
Transmission Fluid XT-2-QOX or MERCON@ equivalent INLET TUBE
for 15 minutes. 7A160
NOTE: Lightly lubricate all O-ring seals before
installing using Motorcraft MERCON@ Multi-Purpose
Automatic Transmission Fluid XT-2-QDX or MERCON@
equivalent.
NOTE: Lightly grease all thrust washers with
petroleum jelly to hold in place during assembly.
1. Mount transmission case in Rotunda Car / Truck
Engine Repair Stand 014-00106 or equivalent.
010685-0
4. CAUTION: While performing the following
step, use care not to overtighten
compressor tool or misalign the piston in its
bore.
Install reverse clutch piston (70402) using Clutch
ROTUNDACAITRUCK Spring Compressor T65L-77515-A. Remove tool
ENGINE REPAIR STAND after installing reverse clutch piston.
014-00106 D11906-8
Front View
2. Rotate transmission so that converter housing is
facing up.
3. NOTE: When installing short fluid inlet tube use
stripe or rib on tube for alignment. Stripe should
be farthest outboard when installed. Rib should
be toward the front.
If removed, install new short fluid inlet tube using
Oil Filter Tube Installer T89T-700 10-G for steel
tube. If installing plastic tube no special tools are
required.
REVERSE
CLUTCH PISTON
70402
09007-8

ALL RIGHTS RESERVED
Rear View
OUTPUT SHAFT HUB
AND INNER RACE BOLTS
(5 REQ'O)
CLUTCH SPRING
COMPRESSOR 09009-8
T65L-nS15-A DIOO8-1A
7. NOTE: Install reverse clutch press~re plate
5. NOTE: The use of two 5/ 16-24 x 3-1 /2-inch retaining ring with opening between the 12 and 3
bolts with the heads removed (for alignment pins) o'clock positions.
is helpful in aligning the inner race into the case.
NOTE: No stack-up clearance measurement
Install reverse clutch return spring assembly and required.
output shaft hub and inner race. Inner race must
be installed with lubrication hole in the 5 o'clock Install reverse clutch pack (five- or six-plate
position. depending on vehicle application) starting with a
(external spline) steel plate. Alternate with
(internal splined) friction plates. Install reverse
clutch pressure plate and reverse clutch pressure
OUTPUT SHAFT
12 O'CLOCK HUB AND INNER RACE plate retaining ring.
70164
REVERSE CLUTCH 12 O'CLOCK REVERSE
PRESSURE PLATE CLUTCH
78066 PRESSURE
PLATE
RETAINING
RING
7D483
REVERSE CLUTCH 6 O'CLOCK

RETURN SPRING 6 O'CLOCK
ASSEMBLY D11848-C
70406 D10686-C 8. Rotate transmission to horizontal position.
6. Attach output shaft hub and inner race to case
with five bolts using a 7 / 16 socket and
alternately tighten to 24-34 N·m (18-25 Ib-ft).
ALL RIGHTS RESERVED
9. NOTE: Be sure No. 13 output shaft thrust washer

is properly seated against tab on case. REVERSE
CLUTCH HUB
Lubricate steel side of the No. 13 output shaft AND LOW ONE-WAY
thrust washer with petroleum jelly and place on CLUTCH ASSEMBLY
rear of case so that bronze side is facing
outward.
NO. 13 OUTPUT SHAFT

THRUST WASHER
78368
08988-8
12. Using petroleum jelly, place the No. 12 output

shaft hub thrust washer on the rear surface of the
hub assembly. Place the output shaft ring gear
D901G-E
assembly into the case.
10. Slide park gear (7A233) onto output shaft (7060)
with thrust surface forward. Install output shaft.
NO. 12 OUTPUT
SHAFT HUB
THRUST WASHER
70422
11. NOTE: When the reverse clutch and low one-way

clutch are installed, the reverse clutch should 012559-8
rotate clockwise. The one-way clutch will hold
and not let the clutch hub rotate
counterclockwise.
Install reverse clutch hub and low one-way clutch
assembly by pressing hub inward and rotating
clockwise over the output shaft hub and inner
race to fully seat.

ALL RIGHTS RESERVED
.;;.1,
13. WARNING: DO NOT OVEREXTEND OUTPUT 15. Install reverse planet retaining ring into reverse
SHAFT RETAINING RING WHEN INSTALLING. clutch hub. Verify retaining ring is fully seated.
MAKE SURE OUTPUT SHAFT RETAINING ...
RING IS SECURELY SEATED IN GROOVE.
Install new output shaft retaining ring onto output
shaft.
REVERSE PLANET
RETAINING RING
D8984-C
16. NOTE: Use a light film of petroleum jelly on the
OUTPUT SHAFT No. SA intermediate brake drum thrust washer.
RETAINING
RING D8988-D Verify that No. SA intermediate brake drum thrust
washer is installed onto intermediate brake drum.
14. Rotate transmission so that converter housing is Make sure tabs are seated properly into slots.
facing up. Install reverse planet assembly into
reverse clutch hub with No. 108 and No. 11 INTERMEDIATE
reverse planet thrust washers. BRAKE THRUST
WASHER
7C096
NO. 11 REVERSE PLANT
THRUST WASHER - REAR
7A166
-----~
D9134-D
D8985-G

ALL RIGHTS RESERVED
17. Verify that the No. 88 forward clutch needle

bearing is installed. If not, apply a light film of
petroleum jelly to forward clutch needle bearing
cylinder assembly and install into front end of
forward clutch with the large 0.0. radius facing
inward.
NO. 8B FORWARD CLUTCH

NEEDLE BEARING
7F374
D9136-C
D9275-D 19. NOTE: Use a light film of petroleum jelly on the
No. 9A forward clutch thrust bearing. Install with
18. Install forward clutch cylinder assembly onto large 0.0. radius facing inward.
intermediate brake drum by rotating until fully
Verify that the No. 9A forward clutch thrust
seated.
bearing is installed into the forward clutch.
NO. 9A FORWARD CLUTCH

THRUST BEARING
FORWARD 70234
CLUTCH
CYLINDER
ASSEMBLY
7A360
INTERMEDIATE
BRAKE DRUM AND
FORWARD CLUTCH
CYLINDER ASSEMBLIES
D9135-C
D9137-E

ALL RIGHTS RESERVED
20. Apply a light film of petroleum jelly to No. Be

forward clutch hub thrust washer and place onto
forward hub and ring gear assembly. Place
forward hub and ring gear assembly into clutch
drum.
FORWARD HUB AND

RING GEAR ASSEMBLY
NO. 8C FORWARD
CLUTCH HUB
THRUST WASHER
70090
NO. 10A FORWARD

PLANET ASSEMBLY
THRUST WASHER
7A166 D9140-E
INTERMEDIATE
BRAKE DRUM AND INTERMEDIATE BRAKE
FORWARD CLUTCH DRUM
CYLINDER ASSEMBLIES 70044
FORWARD CLUTCH
D9138-F CYLINDER
7A089
FORWARD
PLANET
ASSEMBLY
7A398
INTERMEDIATE
BRAKE DRUM
ANDFORWARD~~~
CLUTCH
CYLINDER 09141·D
ASSEMBLIES 09139-0
21. Apply a light film of petroleum jelly to No. 10A
forward planet assembly thrust washer and
place onto forward planet assembly. Tabs on No.
~ OA forward planet assembly thrust washer must
engage slots on forward planet assembly. Place
forward planet assembly into forward hub and
ring gear assembly.

ALL RIGHTS RESERVED
22. NOTE: Apply a light film of petroleum jelly to No. 24. Install input shell onto assembly and rotate until
98 forward clutch thrust bearing to hold in place. fully seated.
Install with large 0.0. radius facing inward.
Verify No. 98 forward clutch thrust bearing is
installed into forward planet assembly.

THRUST BEARING
70234
09144-B
25. Install Clutch Remover / Replacer T89T-700 10-E.
D9142·D
23. Align input shell notches with intermediate brake
drum lugs.
INPUT
SHELL
70084

ALL RIGHTS RESERVED
26. With Clutch Remover / Replacer T89T-700 10-E INTERMEDIATE

attached, lower entire assembly (intermediate SERVO PISTON
brake drum assembly, forward clutch assembly RETAINING RING
and input shell assembly) into case. 7381
CLUTCH REMOVER!
REPLACER
T89T-70010-E
INTERMEDIATE
BRAKE DRUM,
FORWARD CLUTCH,
AND INPUT
SHELL ASSEMBLY
D8965-E
D9012-e
27. Remove service tool.

28. Install intermediate band so that one ear is resting
on the anchor pin.
INTERMEDIATE SERVO
PISTON RETAINING RING
7381
D8964·D
29. NOTE: Apply slight downward pressure to

intermediate band servo retainer while installing
retaining ring.
Install the servo piston spring (70028),
intermediate band servo piston (70021) and the
intermediate band servo retainer. Depress the
intermediate band servo retainer and install the
intermediate servo piston retaining ring.

ALL RIGHTS RESERVED
30. NOTE: Install front intermediate clutch pressure 32. Determine center support assembly thickness by
plate with blank area (no teeth) at 6 and 12 placing Depth Micrometer D80P-420 1-A or
o'clock positions. equivalent over the hole in the center support
Install rear intermediate clutch pressure plate on assembly. Extend micrometer probe until flush
bottom. Install intermediate clutch pack starting with the No.6 center support thrust washer
with internal spline plate and alternate with surface on the opposite side of center support
external spline plates. Install front intermediate assembly. A thrust washer held against the
clutch pressure plate on top. center support assembly as shown will help to
determine when the probe is flush. Record this as
Reading A.
INTERMEDIATE
CLUTCH PRESSURE
PLATE-7BOOS
(FRONT)
STACK-UP CHECK READING A

012808-8
INTERMEDIATE
CLUTCH PACK
Part
08981-D Item Number Description
31. NOTE: This stack-up check measurement only 1 - Depth Micrometer
indicates the amount of space existing between D80P-420 1-A
the center support assembly and the intermediate 2 - Reading A
brake drum. It also will indicate if the unit has been 3 - Depth Micrometer Probe
properly built to this point. Flush with Thrust Washer
Surface
Remove the direct clutch cast iron seal rings from 4 - Thrust Washer on Center
center support assembly for this check. Support
5 7A130 Center Support Assembly
STACK-UP CHECK
CENTER SUPPORT
ASSEMBLY
7A130
NO.6 CENTER SUPPORT HOLE FOR DEPTH

THRUST WASHER MICROMETER
SURFACE 012807-8

ALL RIGHTS RESERVED
33. Install No.6 center support thrust washer into

intermediate brake drum. Make sure it is fully STACK-UP CHECK READING C
seated. Place depth micrometer over hole in
center support assembly and extend micrometer
probe until it contacts the thrust washer. This is
Reading B.
4 CENTER
SUPPORT
ASSEMBLY
7A130 012810-8
STACK-UP CHECK READING B
D12809-8 35. Remove and reinstall two direct clutch cast iron
seal rings to center support assembly, removed
earlier for clearance checks. Install center
Part support assembly with feed holes in 6 o'clock
Item Number Description position. Install the two new feedbolts. Do not
1 - Depth Micrometer tighten at this time.
D80P-420 1-A
2 - Reading B
3 - Depth Micrometer Probe 6 O'CLOCK
Contacting Thrust Washer
4 7F374 Forward Clutch Needle
Bearing (No. 8B)
5 7L326 Center Support Thrust
Washer (No.6)
6 70044 Intermediate Brake Drum
7 7A130 Center Support Assembly
34. Subtract reading A from reading B. Record this as

reading C. Reading C must be within specification
2.06-0.81mm (.081-.032 inch). If final dimension
is outside specified limits, this indicates improper
assembly.
12 O'CLOCK
D9015-C

ALL RIGHTS RESERVED
36. NOTE: Locate one spring leg pointing toward the 38. Position intermediate / overdrive cylinder retaining
6 o'clock position of the transmission. ring over intermediate / overdrive cylinder
Install intermediate clutch return spring with assembly so that snap ring opening is at bottom
dished surface inward. (6 o'clock position) of case for proper fluid
drainback.
SO'CLOCK INTERMEDIATE!
OVERDRIVE
CYLINDER
120'CLOCK RETAINING
RING
70483
INTERMEDIATE TOP OF
CLUTCH RETURN CONVERTER
SPRING HOUSING o 0 0
~f( J!RP~o D10688-D

78070 D9016-E
37. CAUTION: Do not misalign
intermediate/ overdrive cylinder assembly
when installing.
Install intermediate / overdrive cylinder assembly
into case with feed hole in 6 o'clock position
aligning with feed hole in case.
09017-8
1995 F.. 150, F-250, F-350, Bronco, F-Super Duty Powertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
39. NOTE: No stack-up clearance measurement

required.
Install Clutch Spring Fixture T89T-70010-C onto
intermediate/overdrive cylinder assembly. Using
two bolts, attach the tool to the pump face of
case as illustrated. Tighten center bolt to 7 N·m
(65 Ib-in). Seat intermediate / overdrive cylinder
retaining snap ring into case ring groove. Install
one new intermediate / overdrive cylinder feed
bolt. (Do not tighten at this time.)
NO.5 OVERDRIVE
CENTER SHAFT
THRUST BEARING
ASSEMBLY OVERDRIVE CENTER SHAFT-7A658,
7G178 OVERDRIVE RING GEAR-7A153,
PLANET GEAR
OVERDRIVE CARRIER-7B446 AND
COAST CLUTCH CYLINDER ASSEMBLY
D9021-D
42. NOTE: Number of plates in clutch pack is model
dependent.
Install overdrive clutch starting with steel plate
alternating with friction plates. Install overdrive
clutch pressure plate with dot facing outward and
at the 12 o'clock position. Install overdrive clutch
CLUTCH SPRING
FIXTURE ADAPTER
T89T-70010-C3 ... CLUTCH SPRING
COMPRESSOR BAR
pressure plate retainer snap ring with opening at
bottom of case (6 o'clock).
OVERDRIVE 60'CLOCK
T89T-70010-C1
CLUTCH PACK
CLUTCH SPRING
FIXTURE PLATE
T89T-70100-C2 TOOL ASSEMBLY
VIEW A
08975·8
40. Remove clutch spring fixture assembly.

4 1. CAUTION: the input shaft (7017) and
overdrive planet assembly are serviced as
mating components. Do not mix 1995 parts OVERDRIVE
CLUTCH
and prior year service parts. PRESSURE
Verify that the No.5 overdrive center shaft thrust OVERDRIVE PLATE
bearing assembly is on rear face of overdrive CLUTCH RETAINER
PRESSURE SNAP RING
center shaft (7A658). Install overdrive center 70483
shaft, overdrive ring gear, planet gear overdrive PLATE 12 O'CLOCK
78066 D9Q22·D
carrier (78446) and coast clutch cylinder as an
assembly. 43. Check stack-up clearance in three positions 120 0
apart using a feeler gauge. If not within
specification, install correct selective retaining
ring and recheck.
Specification:
2 Plate: 1.33-0.68mm (0.052-0.027 inch)
3 Plate: 1.63-0.98mm (0.064-0.039 inch)

ALL RIGHTS RESERVED
ASSEMBLY (Continued)-
Selective Retaining Rings:

1.55-1.45mm (0.061-0.057 inch)
2.05-1.95mm (0.081-0.077 inch)
2.60-2.50mm (0.102-0.098 inch)
3.10-3.00mm (0.122-0.118 inch)
3.60-3.50mm (0.142-0.138 inch)
D,0889-B
OVERDRIVE CLUTCH 46. Using petroleum jelly to hold i~ plflce, make sure
PRESSURE PLATE
RETAINER SNAP RING that No. 1 pump thrust washer and No. 2A
70483 overdrive sun gear thrust bearing are in place
before installing pump.
44. Align holes and install new oil pump gasket
(7A 136) into case.
NO. 2A OVERDRIVE SUN
GEAR THRUST
BEARING
7C096
NO.1 PUMP
D9024-C saUARECUT THRUST
FRONT OIL WASHER
45. CAUTION: The input shaft and overdrive PUMP SEAL 70014
planet assembly are serviced as mating 70441
D9025-E
components. Do not mix 1995 parts and
Install input shaft (long splined end first) and
thread Aligning Pin 1891-70010-8 into case.

ALL RIGHTS RESERVED
47. CAUTION: Tighten pump bolts alternately to

avoid possible damage.
CAUTION: the input shaft and overdrive
planet assembly, are serviced as mating TIGHTEN BOLTS
TO 24-31 N-m ~ .. ,
components. Do not mix 1995 parts and '.(18-23 LB-FT)
Install the front oil pump assembly into the case.
Orient the filter inlet tube bore toward the 6
o'clock position. Fully seat the front oil pump
assembly using hand pressure only. Do not
use bolts to draw front oil pump assembly
into the case.
6 O'CLOCK
PUMP BOLTS
AND WASHERS
(9 REC'O)
D9027-c
49. Install manual control lever shaft seal (7F337)

using Shift Lever Seal Replacer T74P-77498-A.
SHIFT LEVER .
SEAL REPLACER
T74P-77498-A
ALIGNING PIN
T89T-70010-B
D9026-D
48. CAUTION: Remove input shaft prior to
rotating transmission.
Remove old rubber coated washers from the nine
pump-to-case bolts. Install nine new pump bolt
washers. Remove Aligning Pin T89T-70010-B.
Install nine pump bolts using a 10mm socket.
lighten to 24-31 N·m (18-23 Ib-ft) alternating
bolts. Remove input shaft.
D11907-B
50. Install manual control lever shaft (7C493).

51. Install transmission range (TR) sensor with two
bolts and washers. Do not tighten bolts at this
time.
52. Insert manual control valve detent lever spring
(7A261) and 8mm bolt. lighten to 9-11 N·m
(80-100 Ib-in).
53. Install manual lever shaft retaining pin (7B210)
past case surface.

ALL RIGHTS RESERVED
54. NOTE: Manual valve detent lever (7A 115) must 56. Shift manual valve detent lever to all detent
be seated on flats of manual control lever shaft, positions to check proper engagement of all
and parking lever actuating rod (7A232) must be positions and parking mechanism.
through guide plate. 57. Align Transmission Range (TR) sensor for neutral
Install manual valve detent lever, parking lever gear position using Transmission Range (TR)
actuating rod and nut. sensor (MLP) Alignment Tool T92P-70 10-AH.
58. Using an 8mm socket, tighten bolts to 6-8 N·m
(55-75Ib-in).
59. NOTE: The outer manual control lever must be
seated on the flats of the manual control lever
shaft.
Install the outer manual control lever onto the
manual control lever shaft. The outer manual
control lever should be up and the pin away from
the transmission.
60. CAUTION: A new outer manual control lever
shaft nut must be used to properly secure
outer manual control lever to manual control
lever shaft.
Install a new outer manual control lever shaft nut
using a 15mm socket while holding the outer
manual control lever with a crescent wrench.
lighten the nut to 27-39 N·m (20-29Ib-ft) (cable
J system only).
MANUAL VALVE
DETENT LEVER 61. NOTE: Parking pawl return spring (7D070) end
7A115 rests on inside surface of case.
D7876-E Install parking pawl (7A441), parking pawl shaft
(7D071) and parking pawl return spring on rear
55. NOTE: Manual control valve detent lever spring face.
must be on manual valve detent lever and detent
lever pin must align with manual shift valve
(7C389).
Tighten inner manual valve detent lever nut using a
21 mm crowfoot while holding manual control
lever shaft with crescent wrench. Tighten nut to
41-54 N·m (30-40 Ib-ft).
TIGHTEN NUT TO
41-54 N-m
(30-40 lB-FT)
PARKING SPRING END

PAWL RESTS ON INSIDE
7A441 SURFACE OF CASE D9033-E
INNER MANUAL VALVE

DETENT LEVER NUT
09238-0

ALL RIGHTS RESERVED
62. If removed, install parking pawl abutment with 64. Place new extension housing gasket (7086) on
new Torx@ head screw (T40 bit) and tighten to extension housing (7A039).
22-27 N·m (16-20 Ib-ft).
EXTENSION
HOUSING
7A039
PARKING PAWL TIGHTEN TORX~

ABUTMENT SCREW TO
7G101 22-27 N·m
(16-20 LB-FT)
D9038-B
D9034-F
65. NOTE: The two bottom extension housing bolts
63. NOTE: Make sure parking guide support plate are slightly shorter on 4x2 vehicles and slightly
dimple is facing inward and parking lever longer on 4x4 vehicles.
actuating rod is in parking rod support plate slot. Install extension housing and wiring bracket on
Attach two parking rod guide plate bolts and rear of case (at approximately the 10 and 11
washers using a 13mm socket. Tighten to 22-27 o'clock positions). Install nine bolts using 13mm
N·m (16-20 Ib-ft). socket. Tighten bolts to 27-39 N·m (20-29Ib-ft).
12 O'CLOCK
PARKING ROD
OUTER PLATE
70419
D9035-E

ALL RIGHTS RESERVED
66. Install extension housing seal, using Extension

Housing Seal Replacer T61L-7657-B.
lli~o
EXTENSION
HOUSING SEAL
REPLACER
T61L-7657-B
Dl1. .1A
67. Rotate transmission so that pan surface is facing

up. Tighten three feedbolts using 13mm socket
into intermediate / overdrive cylinder and center
support assembly. Tighten the front feedbolt
to 8-14 N·m (6-10 Ib-ft). Tighten both rear
feedbolts to 11-16 N·m (8-12Ib-ft).
o- RUBBER (9)
D904o-G
1lGHTEN FRONT
FEED BOLT TO
8-14 N·m
(8-10 FT·LB)
DIQ2O-1A
68. CAUTION: Use care not to damage rubber

check balls.
NOTE: The steel EPC check ball is a .25 inch
diameter steel ball that is smaller than the rest.
Install steel EPC check ball and nine rubber check
balls. Refer to the following illustration for check
ball location.
1995 F-150, F-250, F-350, Bronco, .F-Super Duty Powertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
69. Install separating plate to case gasket. 71. Install separating plate reinforcing plate. Install
three bolts using an 8mm socket with the
stamped word ··UP" visible using an 8mm socket.
SEPARATING PLATE
TO CASE GASKET Tighten to 9-11 N·m (80-100 Ib-in).
7C155
BOLTS
TIGHTEN TO
9-11 N-m
(80-100 LB-IN)
SEPARATING PLATE
REINFORCING
PLATE
7F282
()
D9043-C
72. Install main control to separating plate gasket.
70. NOTE: Check placement of steel EPC check ball.

Install valve body separating plate (7A008). MAIN CONTROL
TO SEPARATING
PLATE GASKET
70100
D9044-D
D9042·D

ALL RIGHTS RESERVED
73. Install solenoid screen assembly into separator

plate by pushing in and rotating to lock. MAIN CONTROL
VALVE BODY
7A100
CHECK
PLACEMENT OF
MANUAL SHIFT
VALVE
7C389 D9047-c
76. Install main control valve body install two nuts
D8960-D finger tight.
77. NOTE: Prior to installing solenoid body assembly,
74. Install accumulator body assembly over studs.
coat the case connector bore with petroleum jelly
Install two nuts and 11 bolts finger tight.
or equivalent.
Install solenoid body assembly over stud. Install
ACCUMULATOR
BODY nine Torx@ bolts using a T30 bit and one nut finger
ASSEMBLY tight.
7G422
D9045-C
75. Lower main control valve body (7A 100) over
studs. Align manual shift valve with manual valve
detent lever.
D9049-B

ALL RIGHTS RESERVED
78. Tighten all accumulator body, upper and lower

control body and solenoid body nut and bolts to OIL PAN
9-11 N·m (80-100 Ib-in). MAGNET OIL PAN TO
7L027 CASE GASKET
·SOLENOID 7A191
TIGHTEN TORX~ BOLTS BODY
AND NUT TO ASSEMBLY
9-11 N-m 7G391
(80-100 LB-IN)
D905O-C
79. CAUTION: Do not reuse old filter assembly
and seal.
Install a new filter assembly and seal by
lubricating the seal with transmission fluid and
pressing the filter into place. D9051-C
81. Attach pan with bolts using a 10mm socket.
Tighten bolts to 14-16 N·m (10-12 Ib-ft).
D8955-C
80. Place oil pan magnet on dimple in bottom of
transmission oil pan (7A 194). Install new oil pan 09052·8
to case gasket (7A 191) on transmission.

ALL RIGHTS RESERVED
82. CAUTION: The input shaft and overdrive 3. CAUTION: Use care when installing torque
planet assembly are serviced as mating converter (7902) to avoid damage to the
components. Do not mix 1995 and prior year front pump support seal (7L323).
service parts. NOTE: Check the converter crankshaft pilot for
Rotate transmission so transmission oil pan is nicks or damaged surfaces that could cause
facing down and install input shaft, long splined interference when installing the transmission to
end first. engine. Check the converter impeller hub for
nicks or sharp edges that would damage the
pump seal.
INPUT NOTE: Check the seating of the torque converter
SHAFT 12 O'CLOCK by placing a straightedge across the converter
7017 housing. There must be a gap between the
converter pilot face and the straightedge.
r
6 O'CLOCK 08953-0
STRAIGHT EDGE
INSTALLATION

Torque Converter Handles T81 P-7902-C
DIOI4-1A
Install torque converter using Torque Converter
Transmission Handles T81 P-7902-C. Carry torque converter
Before installing transmission, check wiring harness with the handles in the 6 and 12 o'clock positions.
for damage. Check connectors for electrical integrity Push and rotate the torque converter onto the
(terminal condition, corrosion, contamination and seal front oil pump assembly until it bottoms out.
integrity). Repair or replace as required. 4. Remove converter handles.
1. Place transmission onto Rotunda E40D 5. Check condition of transmission fluid filler tube
Transmission Adapter 014-00763 or equivalent. a-ring, replace if damaged. Install oil filler tube
2. On 4x4 models only, install transfer case to (7A228).
transmission. Refer to Section 07-07A or 07-07B. 6. Rotate torque converter studs to align with
On F-Super Duty Models, install transmission flywheel mounting holes.
mounted parking brake. Refer to Section 06-05.

ALL RIGHTS RESERVED
INSTALLATION (Continued)
7. Raise transmission into position while watching 11. NOTE: Case connector fitting should be held with
for any obstructions. Do not allow torque wrench to prevent it from moving when tightening
converter drive flats to disengage from pump tube nut.
gear. Rubber converter drain plug cover may be Install transmission fluid cooler tubes to
removed to aid in the alignment of the converter transmission fittings. Tighten to 24-31 N·m (18-23
studs. Use care not to damage the flywheel Ib-ft) on all applications except F-Super Duty
(6375) and converter pilot. The torque converter vehicles. Tighten transmission fluid cooler tube
must rest squarely against the flywheel. This fittings to 24-31 N·m (18-23 Ib-ft) for F-Super
indicates that the torque converter pilot is not Duty applications.
binding in the engine crankshaft (6303).
TRANSMISSION OIL
COOLER TUBE
8. Install transmission-to-engine bolts. Alternately

snug-up bolts. Alternately tighten bolts to 51-70
N·m (38-52 Ib-ft) for gas engine applications, or to
53.1-71.9 N·m (39-53Ib-ft) for diesel engine
applications. 12. Install rear engine support (6A023) and
transmission retaining bolts. Make sure that
wiring harness is properly routed.
13. Remove safety strap and universal high lift
transmission jack.
14. Rotate crankshaft using a 15/ 16-inch socket on
front pulley bolt to gain access to torque
converter studs. Install new converter stud nuts
using a 9/ 16-inch socket. Tighten to 34-46 N·m
(25-34 Ib-ft).
D9185-C
9. Install converter housing access plug (7N171), if

removed.
10. Shift transmission to the left and position three 15. Install starter motor (11001). Refer to Section
way catalytic converter (TWC)(5E212) to the 03-06A or 03-068.
exhaust manifolds (9430) (5.8l lightning Truck
applications only). Refer to Section 09-00.
1995 F-150, F-250, F-350, Bronco, F-Super Duty Powertrain. Drivetrain July 1994
ALL RIGHTS RESERVED
16. Install rear engine plate cover and lower dust

cover bolts. lighten to specifications indicated in
Specifications. in this section.
D9193-8
Crossmember Installation, F-Series Vehicles
UGHTNING TRUCK
F-150-350 (4x2) 4x2
•
VIEWY
F-150 - F-350, BRONCO (4x4)
AND F-SUPER DUTY
VIEWY

ALL RIGHTS RESERVED
Part Part
1 6096 Rear Engine Support 6 N802114 Bolt
Bracket (LH) 7 6A023 Rear Engine Support
2 60091 Insulator and Retainer 8 N800937 Nut
3 390066 Screw and Washer 9 N621945 Nut and Washer
4 7108 Transmission Support A - Tighten to 59-77 N·m
Bracket (43-57 Lb-Ft)
5 6096 Rear Engine Support B - Tighten to 82-109 N·m
Bracket (RH) (60-80 Lb-Ft)
(Continued)
17. Completely seat solenoid body connector into

solenoid body assembly receptacle by pushing on
the top of the connector. An audible click
indicates full contact. Verify connection by pulling
on harness.
TIGHTEN BOLTS
TO 9-11 N-m
(80-100 LB-IN)
09196·0
19. On 4x4 models only, install new wire harness
locators into rear engine support.
20. Install new wire harness locator into extension
housing wire bracket.
D9195-C
21. Install four-wheel drive switch connector, if
18. Install transmission heat shield (7A434) with equipped.
off-set bending inward. Tighten to 9-12 N·m 22. Connect transfer case shift linkage, if equipped.
(77-104Ib-in). Refer to Section 07-078.
23. Install Transmission Range (TR) sensor
connector. An audible click indicates full
connection.
24. Install shift cable, or linkage on F-Super Duty
Motorhome and Commercial vehicles. Refer to
Section 07-05.
25. Install parking brake cable (F-Super Duty). Refer
to Section 06-05.
26. Install muffler (5230) and tailpipe and crossover
assembly. Refer to Section 09-00 (5.8l lightning
Truck and 7.3l IDI Diesel applications only).
27. Install rear driveshaft. Refer to Section 05-01.
28. On 4x4 models only, install front driveshaft. Refer
to Section 05-0 1.
ALL RIGHTS RESERVED
29. Remove safety stands and lower vehicle. Whenever a transmission has been disassembled to
30. NOTE: When the battery has been disconnected replace worn or damaged parts or because the valve
and reconnected, some abnormal drive body sticks from foreign material, the torque converter
symptoms may occur while the powertrain and transmission fluid cooler must be cleaned by using
control module (PCM)( 12A650) relearns its a mechanically agitated cleaner, such as Rotunda
adaptive strategy. The vehicle may need to be Torque Converter / Oil Cooler Cleaner 014-00028 or
driven 10 miles or more to relearn the strategy. equivalent.
Connect battery ground cable (14301). Flush the torque converter of the remaining solvent
using this procedure:
31. Fill the transmission to the proper level with
Motorcraft MERCON@ Multi-Purpose Automatic 1. Thoroughly drain the remaining solvent through
Transmission Fluid XT-2-QDX or MERCON@ the converter housing access plug (7N171).
equivalent. Refer to Fluid Capacity Chart under 2. Add 1.9 liter (2 qt.) of clean transmission fluid to
Specifications. the torque converter. Agitate by hand.
3. Thoroughly drain the solution through the
converter housing access plug.
Transmission
Transmission Cooler and Lines, Back
CAUTION: The friction clutch plates, band and
synthetic seals should not be cleaned in a vapor Flushing and Cleaning
degreaser or with any type of detergent solution. 1. Conduct back flushing with a Rotunda Torque
To clean these parts, wipe them off with a lint-free Converter / Oil Cooler Cleaner 014-00028 or
cloth. New clutch plates or bands should be soaked in equivalent. Test your equipment to make sure
the specified transmission fluid for 15 minutes before that a vigorous fluid flow is present before
being assembled. proceeding. Replace the system filter if flow is
weak or contaminated.
Clean all other parts with suitable solvent and use
moisture-free air to dry off all parts and clean out fluid 2. To aid in attaching the cleaner to the transmission
passages. steel cooler lines, connect two additional rubber
hoses to the transmission end of the steel
transmission cooler lines as described below.
• Connect the cleaner tank pressure line to the
Main Control Valve Body steel transmission cooler return line (longest
1. Clean all parts thoroughly in clean solvent and line).
blow dry with moisture-free compressed air. • Connect a tank return hose to the steel
2. Inspect all valve and plunger bores for scores. transmission cooler pressure line (shorter line).
Check all fluid passages for obstructions. Inspect Place the outlet end of this hose in the solvent
all mating surfaces for burrs and scores. tank reservoir.
3. Inspect all springs for distortion. Check all valves 3. Turn on solvent pump and allow the solvent to
and plungers for free movement in their circulate a minimum of 5 minutes (cycling switch
respective bores. Valves and plungers, when dry, on and off will help dislodge contaminants in
must fall from their own weight in their respective cooler system).
bores. 4. Switch off the solvent pump and disconnect the
4. Roll manual shift valve (7C389) on a flat surface solvent pressure hose from the transmission
to check for bent condition. cooler return line.
5. Use compressed air to blowout the cooler(s) and
lines (blow air into the transmission cooler return
line) until all solvent is removed.
Converter and Oil Cooler
When internal wear or damage has occurred in the
transmission, metal particles, clutch plate material or
band material may have been carried into the torque
converter (7902) and transmission fluid cooler. These
contaminants are a major cause of recurring
transmission troubles and must be removed from the
system before the transmission is put back into
service.
ALL RIGHTS RESERVED
6. Remove the rubber return hose from the 2. Inspect the rollers, sprags, springs and cage for
remaining steel cooler line. excessive wear or damage.
Output Shaft
1. Inspect the bearing surfaces of the output shaft
(7060) for wear or scores. If excessive wear or
scores are found, replace output shaft and
inspect mating components.
2. Check the splines on the output shaft for wear.
Replace the output shaft if the splines are
excessively worn. Inspect all the bushings for
wear. Replace if worn or damaged.
Electrical Connectors
Any time an electrical connector or solenoid body is
disconnected, inspect the connector for terminal
condition, corrosion and contamination. Also inspect
PRESSURE the connector seal for damage. Clean, repair or
CONNECTION replace as required.
TO RESERVOIR
D12277-A
Case
Forward, Direct, Intermediate, Overdrive, Inspect the case assembly for cracks and stripped
Coast and Reverse Clutches threads. Inspect the gasket surfaces and mating
surfaces for burrs. Check the vent (7034) for
1. Inspect the clutch cylinder thrust surfaces, piston obstructions, and check all fluid passages for
bore, and clutch plate splines for scores, burrs or obstructions.
wear. Replace the clutch cylinder if it is badly
scored or damaged. Inspect the case assembly bushing for scores. Check
all parking linkage parts for wear or damage.
2. Check the fluid passage in the clutch cylinder for
obstructions. Clean out all fluid passages. Inspect If the transmission case assembly thread is damaged,
clutch piston for scores and replace if necessary. service kits (helicoil) may be purchased from local
Inspect the check balls for freedom of movement. jobbers. To service a damaged thread, follow
procedures furnished in the helicoil kit.
3. Check the clutch release spring for distortion and
cracks. Replace the spring if it is distorted or
cracked.
4. Inspect the friction clutch plates, steel clutch Planet Assemblies
plates, and clutch pressure plate for worn or
scored surfaces. Replace all parts that are NOTE: Individual parts of the planet assemblies are
scored, burred or burnt. not serviceable.
5. Check the clutch plates for flatness and wear on 1. The pins and shafts in the planet assemblies
the clutch hub splines. Discard any plate that should be checked for loose fit and / or damage.
does not slide freely on the splines or that is not Use a new planet assembly if either condition
flat. exists.
6. Check the clutch hub thrust surfaces for scores 2. Inspect the pinion gears for damaged or
and the clutch hub splines for wear. Replace all excessively worn teeth.
worn parts. 3. Check for free rotation of the pinion gears.
4. Check for damage in the overdrive planet
assembly.
One-Way Clutch
1. Inspect the outer and inner races for scores or
damaged surface areas where the rollers or Thrust Bearings
sprags contact the races. Wash the thrust bearings thoroughly in cleaning
solvent. Blow the bearings dry with compressed air.
ALL RIGHTS RESERVED
Make certain the bearings are clean and then lubricate

with transmission fluid. Replace any bearings and
races which show signs of pitting or roughness.
Torque Converter NOTE: Mineral spirits used to clean the torque

When internal wear or damage has occurred in the converter must be fresh, non-chlorinated and
transmission, metal particles, clutch plate material, or non-halogenated.
band material may have been carried into the torque Flush the torque converter of the remaining solvent
converter (7902) and transmission fluid cooler using this procedure.
(7A095). These contaminants are a major cause of 1. Thoroughly drain remaining solvent through the
recurring transmission troubles and MUST be drain plug.
removed from the system before the transmission is
put back into service. 2. Add 1.9L (2.0 U.S. quarts) of clean transmission
fluid to the converter. Agitate by hand.
Whenever a transmission has been disassembled to
replace worn or damaged parts or because the valve 3. Thoroughly drain solution through the drain
body valves stick repeatedly from foreign material, the plug.
torque converter, transmission fluid cooler and
transmission fluid cooler tubes and hoses MUST be
cleaned by using a mechanically agitated cleaner,
such as Rotunda Torque Converter / Oil Cooler Cleaner
Transmission Fluid Cooler Tube Leakage Using the old line as a guide, bend the new line as
When fluid leakage is found at the transmission fluid required. Add the necessary fittings, and install the
cooler (7A095), the transmission fluid cooler must be- line.
·:Jeplaced. Refer to Section 03-03. After the fittings have been tightened, check and add
When transmission fluid cooler steel lines must be fluid as necessary. Check for fluid leaks.
replaced, each replacement line must be fabricated
from the same size inside diameter and length steel
line as the original line.
SPECIFICATIONS
Automatic Transmission Refill Capacity Approximate capacity includes transmission fluid

cooler (7A095) and transmission fluid cooler tubes.
Fluid level indicator (7A020) should be used to
Motorcraft Mercon~ Multi-Purpose Automatic Transmission
Fluid Ford E4AZ-19582-8 or equivalent meeting Ford
determine actual oil requirement and oil specifications.
Specification ESP-M2C 166-H Check level at operating temperature. DO NOT
OVERFILL. An additional .3 quart (.3 liter) is required if
Transmission vehicle has an auxiliary transmission fluid cooler.
Type Liters Quarts
NOTE: The F-Super Duty Motorhome commercial
4x2 14.8 15.7
chassis used an additional 1.0 quart (0.9 liter) of oil for
4x4 15.3 16.2 the auxiliary transmission fluid cooler.
Clutch Plates
CLUTCH PLATE USAGE AND CLEARANCE SPECIFICATIONS
Selective Snap Rings
Clutch
Intermediate Clutch
78442
Steel
78164
Friction Clearance Part Number I Thickness
(In.)
4.9L 1 2 - - I -
(Continued)
ALL RIGHTS RESERVED
CLUTCH PLATE USAGE AND CLEARANCE SPECIFICATIONS (Cont'd)

Selective Snap Rings
78442 78164 Thickness
Clutch Steel Friction Clearance Part Number (In.)
5.0L I 5.8L I 7.3LO I 7.5L 2 3 .063-.029 In. - -
(1.61-0.73mm)
Direct Clutch
4.9L/5.0L 3 3 .081-.045 In. 377128-8 .087-.083
(2.05-1.14mm) 377127-8 .078-.074
5.8L/7.5L 4 4 .081-.045 In. 377126-8 .069-.065
(2.05-1.14mm)
7.3L 01 Diesel 5 5 .081-0.45 In. 377437 .060-.056
(2.05-1. 14mm)
Overdrive Clutch
4.9L I 5.0L 15.8L 2 2 .052-.027 In. E9TP-7B421-EA .142-.138
( 1.33-0.68mm) E9TP-7B421-0A .122-.118
E9TP-7B421-CA .102-.098
7.5L, 7.3L 01 Diesel 3 3 .064-.039 In. E9TP-7B421-BA .081-.077
( 1.63-0.98mm) E9TP-7B421-AA .061-.057
Coast Clutch
All 2 2 .050-0.30 In. N804952-8 .089-.085
(1.27-0.76mm) N804951-8 .073-.069
N804950-8 .057-.053
Forward Clutch
4.9L/5.0L 2 3 .055-.030 In. 377437-8 .056-.060
(1.40-0.76mm) 377127-8 .074-.078
5.8L I 7.3LO I 7.5L 2 4 - 377444-8 .092-.096
386841-8 .110-.114
386842-8 .128-.132
Reverse Clutch
4.9L I 5.0L 15.8L 5 5 .104-.027 In. N805207-8 8 .074-.0788
(2.64-0.68mm)
7.3LO/7.5L 6 6 .113-.027In. - -
(2.87-0.68mm)
a A non-selective snap ring.
NOTE: The above chart does not reflect apply, pressure or wave plates.
T0125678
Torque Specifications
Cooler Tube, Transmission, 5 I 16 12-24 9-18
Description N·m Lb·Ft 0.0.
4.9/5.0/5.8L Eng. Plate to Trans. 17-23 12-17 Cooler Tube, Motorhome, 3 I 80.0. 22-30 16-22
7.5L Engine Plate to Trans. 17-23 12-17 Cooler Tube, Motorhome, 5 I 16 16-24 12-18
Center 8upport to Fluid Feed 11-16 8-12 0.0.
Center 8upport to Hub 9-13 80-120 Auxiliary Cooler Tube, 9-18 7-13
(Lb-In) Transmission, 5 I 16 0.0.
-. Auxiliary Cooler Tube, Motorhome, 22-30 16-22
Connector-Cooler Line to Case 24-31 18-23
3/80.0.
Conn. 3/8 Cooler Line Motorhome 24-31 18-23
Auxiliary Cooler Tube, Motorhome, 16-24 12-18
Connector - Radiator-to-Tube 23-31 17-23 5/160.0.
Connectors, Radiator-to-Tube, 27-31 20-23 Control Assembly to Pump 24-31 18-23
Motorhome, 3/80.0.
Torque Converter Drain Plug 28.5-31 21~23
Motorhome 51 16 0.0. 24-30 18-22
Dust Cover to 7.3L Plate 17-23 12-17
(Continued)
(Continued)
1995 F-150, F-250, F-350, Bronco, F-8uper Duty Powertrain, Drivetrain July 1994

ALL RIGHTS RESERVED
Description N·m Lb·Ft Description N·m Lb-Ft

Dust Cover to 7.5L Plate 3-7 30-60 Stator Support to Pump Body 9-11 80-100
(Lb-In) (Lb-In)
Dust Cover to Case 4.9/5.0/5.8L 17-23 12-17 Trans. to 4.9/5.01 5.8L Engine 52-70 38-52
Dust Cover to Case 7.3L 17-23 12-17 Trans. to 7.3L Engine 53-72 39-53
Extension Housing to Case (4x2) 27-39 20-29 Trans. to 7.5L Engine 52-70 38-52
Extension Housing to Case (4x4) 33-54 24-40 Trans. to 7.5L Engine 52-70 38-52
Extension to Rear Engine Mount 81-108 60-80 Trans. to 5.8L Engine over 8500 52-70 38-52
(4x2) No.
Extension to Rear Engine Mount 81-108 60-80 Valve - 3/8 Cooler Line - 24-31 18-23
(4x4) Motorhome
Extension to Rear Engine Mount - 68-95 50-70 Valve Assembly - Cooler Check 24-31 18-23
Motorhome to Case
Transmission Fluid Filler Tube to 33-47 24-35 Valve Control Body to Case - 9-11 80-100
7.3L Engine Long (Lb-In)
Transmission Fluid Filler Tube to 4-6 39-57 Valve Control Body to Case - 9-11 80-100
Intake Manifold - 7.3L (Lb-In) Short (Lb-In)
Transmission Fluid Filler Tube to 17-23 12-17 Valve Control Body to Case - Nut 9-11 80-100
Manifold - Nut 4.9/5.8/7.5 (Lb-In)
Flywheel to Torque Converter - 34-46 25-34
Nut
Transmission Heat Shield to 9-11 80-100 SPECIAL SERVICE TOOLS/EQUIPMENT
Solenoid Body (Lb-In)
Inner Lever to Manual Control 41-54 30-40 SPECIAL SERVICE TOOLS REQUIRED
Shaft
Tool Number /
Inner OWC Race to Case 24-34 18-25 Description illustration
Line Pressure to Case - Plug 8-16 6-12
T50T-l00-A
~
Lower Control Body to Main 9-11 80-100 Impact Slide Hammer
Control Body (Lb-In)
T50T-1OG-A
Main and Lower Control Body to 9-11 80-100
Case (Lb-In) T59L-l00-B
Impact Slide Hammer
~
Main Accum. and Sol. Body to 9-11 80-100
Case (Lb-In)
T51L-1GO-B
Manual Lever to Shaft - Nut 27-39 20-29
T58L-l01-B
Transmission Range Sensor 6-8 55-75
~
(Lb-In) Puller
a 1Drive Cylinder Fluid Feed 8-14 6-10 T58L-101-B
Oil Pan Drain Plug 20-34 15-25 T77F-1176-A

Oil Pan to Case 14-16 10-12 Threaded Drawbar
Oil Pump Body to Case
Parking Rod Support to Case
24-31
22-27
18-23
16-20 ~ T77F-1178-A
Parking Rod Guide Plate to Case 22-27 16-20
Positive Detent Spring to Case 9-11 80-100 T78P-3504-N
~
(Lb-In) Locknut Pin Remover
Reinforcing Plate to Case 9-11 80-100
(Lb-In)
Solenoid Body to Case 9-11 80-100 T71P-3504-N
(Lb-In)
T61L-7657-B
Speedometer Plug to Extension
Housing
4-6 36-54
(Lb-In)
Extension Housing Seal
Replacer @? T81L-7867-B
Starter Motor to Engine Plate 27-46 20-34
4.9/5.8L (Continued)
Starter Motor to Engine Plate 7.5L 27-46 20-34
Outer Manual Lever Nut 27-39 20-29
(Continued)

ALL RIGHTS RESERVED

(Continued)
Description Illustration Description illustration
T77L-7697-C T89T-70010-G
Extension Housing Bushing Oil Filter Tube Installer
Replacer
T77L-7117eC TilT-70010-0
T77L-7697-D T88C-77000-AH
Extension Housing Bushing Return Spring Compressor
Remover
T77L-7117-0
T80L-7902-A T74P-77248-A
End Play Checking Tool Seal Remover
TIOL·7102-A
T81 P-7902-C T74P-7724I-A

Torque Converter Handles
T74P-77498-A
Shift Lever Seal Replacer
T74P-77481-A
TI1 P·7102-C
T65L-77515-A ,
T71 P-19703-C
Clutch Spring Compressor
a-Ring Tool
T89T-70010-A TIIIL·77515-A
Pump Puller Adapter
T92P-70010-AH
Sensor (MLPS)
TilT-7001 G-A
T89T-70010-B
Aligning Pin
T77L-77548-A
Lip Seal Protector
T89T-70010-C
Clutch Spring Fixture
(\~~\/C1
T77L·7754"A
C2",\}) #III
T63L-77837-A
Front Pump Seal Replacer
TilT-7001 o-e
T89T-70010-E
Clutch Remover / Replacer
TI3I.·77I37·A
T92T-7B200-AH
VRV Setting Gauge Block
TilT·7001 G-e
T89T-70010-F
Clutch Spring Compressor T83T·78200- AH
Plate
(Continued)
TI8T·7oo1Q-f
(Continued)

ALL RIGHTS RESERVED

(Continued)

014-00028 Torque Converter / Oil Cooler Cleaner
T92T-77110-AH
014-00106 Car / Truck Engine Repair Stand
Rear Case Bushing Replacer
021-0054A Leak Test Kit
014-00763 E40D Transmission Adapter
007-0041B Super Star II Tester
T77L-7902-R 007-0085C Transmission Tester

Converter Clutch Holding Tool 105-00051 73 Digital Multimeter
007-00033 EEC-IV Go-Pin Breakout Box
007-00086 Transmission Range (TR) Sensor
T77L-7I02-A (UMLPS" Manual Lever Position Sensor
Cable)
T76L-7902-C
Converter Clutch Torquing Tool 007-00500 New Generation Star Tester
T7IL-7I02-C

TOOL-1175-AC Seal Remover
D80P-4201-A Depth Micrometer
D89L-77000-A Banding Tool

ALL RIGHTS RESERVED
07-018-1 Transmission, Automatic, C6 07-018-1
~ SECTION 07-0 1B Transmission, Automatic, C6

VEHICLE APPLICATION 07·018·1 IN-VEHICLE SERVICE (Cont'd.)
DESCRIPTION AND OPERATION Oil Cooler Lines .••••••••••....•....•.••..•..........•••••.•••...07-0 18-27
C6 Automatic Transmission ................••....•.......•..07-018·1 Park/Neutral Position Switch ................••.•••..•.•.07-018-31
Geartrain 07·018·9 Shift Linkage, Internal and External ....•...•••........07-018-31
Main Control Valve 80dy .................•....................07·018·9 Vacuum Diaphragm....••....•••••••.•............•.•.•.•••••••O7-018-29
Main Geartrain Components ........••.•....................07·018·9 REMOVAL
Compound Planetary Gears.••...........................07·01 8·9 Intermediate 8and ...•..•..........•....•....•....•.......••...07-018-32
Input Shaft .•.•.••.•...••.........................................07·018·9 Transmission .............•.•••••••.............••..••......•....•07-018·32
Output Shaft .......•......•••.•.........•.•.......•.••..........07·018·9 Transmission Fluid Drain and Refill
Oil Pump •...........•............•..............................•.....07·018-9 Procedure ...•••••....•.•••......•••...••........•........•.•••.07-018-31
Torque Converter ......................................••........07·0 18·9 DISASSEM8LY
Transmission Identification ..•.•............................07·018·2 Transmission ......•..•••.•••...•..•.•••••••••....••.••••.•••..•..07-018-33
Transmission Range Selector and Shift DISASSEM8LY AND ASSEM8LY OF
Pattern...............•.................•.••.••.•...................07-018·9 SU8ASSEM8LIES
DIAGNOSIS AND TESTING Direct Clutch ..•••.....••..••.....••••••.••••••••••.•••..••...•.••07·018·51
Component Tests ..•..........•...............••..•.....••..•..07-018·17 Forward Clutch•......................•..•••....•..•.•••••••••...07-018-54
Transmission Fluid Condition .....•...................07-018·18 Governor....................•••...•.....•..........•...•.•.•••••.••07-01 B-62
Transmission Fluid Leakage Checks.....•..••.••.•07·018-18 Input Shell and Sun Gear .......•.•••.•••.......•.•.........•07-0 1B-57
Transmission Fluid Level .•....................•.....••..07-018·17 Intermediate Servo •••••••.•.....•.••••••••...•.•••••••••••••.•07·01B-60
Inspection and Verification .........•••.••...•...............07·018·9 Main Control Valve Body ••...•.•..•••.••..••••••.•••••••••••07-o1B-43
Pinpoint Test .................•..•..............................•.07-018·16 Output Shaft Hub and Ring Gear •••••••••••••••••....•.••07-01 B-62
Symptom Chart ....•.........••.................................07-018·10 Pump.............................•••........................••...•.•.07-o1B-48
Transmission Oil Cooler Flow.......•.•.................u07-0 18-20 Reverse Clutch ...........•.....................•.•.•.•..•..•••••07-0 1B-60
Air Pressure Tests ............................•.....•••••.,;.07-018-26 Torque Converter Checks ..••••••..............•.••...•....07-o1B-64
Engine Idle Speed .•.•......................................07-018·21 Overrunning Clutch Check••••....••••••••••..•.........07-01B-64
Engine Vacuum Procedure ............••......•••......07-018-24 Stator to Impeller Interference
Governor .•••..............••.•.•.•.....•....•............".....07-018-23 Check •................•.•.•••...••.•••..•.•...•••............•07-01B-64
Line Pressure Test ...•.•............................••.....07-018-23 Stator to Turbine Interference Check .......•.....07-01 B-64
Shift Linkage ..••...•............•......•..•...................07-018-21 Torque Converter End Play Check .....•......••••••07-01 B-65
Shift Point Road Test ...•.......................•...•......07-0 18-22 ASSEM8LY
Stall Speed Test ..........•................•••....•....••....07-018-21 Transmission .•..•••••.•••...........•.••••.•........••••••••••...07-018-66
Vacuum Diaphragm Test Off-Vehicle .....•...•.••..07-018-26 INSTALLATION .
Vacuum Diaphragm Test On·Vehicle 07-018·26 Transmission ..........................................••••..••••.07-01 B·73
Vacuum Pump Procedure •••••••••..••••••...•••••••••••07-018·25 CLEANING AND INSPECTION
Vacuum Supply Test ....•.•..................••....•....•..07-018-25 Torque Converter and 011 Cooler.•.•••.•••....••..•.....07-Q1B-76
IN-VEHICLE SERVICE ADJUSTMENTS
Extension Housing ..........•...•..........•............•.....07-018-30 Intermediate Band ...................................••.•••••.•07-Q1B-76
Extension Housing Bushing and Rear Park/Neutral Position Switch ...•••......•......•........07-01B·77
Seal 07-018-29 SPECIFICATIONS
Governor 07-018-31 Shift Speeds•••................•.•.••................•••••••••.•••07-o1B-81
Intermediate Servo .............................••.......•..•••07-018-28 SPECIAL SERVICE TOOLS/EQUIPMENT •••••••..••••..•07-01B-83
Main Control Valve Body ............................•••.•.•.07-018-27
VEHICLE APPLICATION
F-250, F-350 4x2 and F-250, F-350 4x4 Vehicles with
C6 Automatic Transmission
[)ESCRIPTION AND OPERATION
C6 Automatic Transmission Only one (intermediate) band is used in the C6

The C6 transmission is a three-speed unit capable of transmission. This along with the forward clutch is
used to obtain intermediate gear.
providing automatic upshifts and downshifts through
the three forward gear ratios. The transmission is also
capable of providing manual selection of first and
second gears.
The converter housing and the fixed splines which
engage the splined outside diameter of the
low-reverse clutch steel plates are both cast integrally
into the case.
ALL RIGHTS RESERVED
Transmission Identification
The identification tag is attached to the intermediate MONTH BUILD DATE CODE
servo lower front cover bolt. The first line on the tag
shows the transmission model prefix and suffix. A
number appearing after the suffix indicates that the
internal parts in the transmission have been changed
after initial production start-up. For example, a
PGD-JF model transmission that has been changed
internally would read PGD-JF 1. Both transmissions
are basically the same, but some service parts in the
PGN-JF transmission are slightly different than the
PGD-JF1 transmission. Therefore, it Is important ASSEMBLY PART
that the codes on the transmission identification NUMBER PREFIX
tag be checked when ordering parts or making AND SUFFIX
D1926-5
inquiries about the transmission.
ALL RIGHTS RESERVED
C6 Automatic Transmission, Exploded View
i
p
Q
ALL RIGHTS RESERVED
Part Part
1 7902 Torque Converter 35 7A548 Forward Clutch Piston Inner
2 87650-S Converter Drain Plug, Seal
1/8-27, Dryseal Tapered 36 7A262 Forward Clutch Piston
Thread 37 70256 Forward Clutch Piston
3 7017 Input Shaft Spring Ring
4 - Front Oil Pump Seal 38 7B070 Forward Clutch Piston Oisc
(Part of 7A 103) Spring
5 - Front Oil Pump Bushing 39 377127-S Retaining Ring
(Part of 7A 103) 40 7B066 Forward Clutch Front
6 - Front Oil Pump Body Pressure Plate
(Part of 7A 103) 41 7E085 Forward Clutch Wave Spring
7 58619-S2 Bolt 42 7B442 Forward Clutch External
8 - Pump Driven Gear Spline Plate - (Steel)
(Part of 7A 103) 43 7B164 Forward Clutch Internal
9 - Pump Drive Gear Spline Plate - (Friction)
(Part of 7A 103) 44 7B066 Forward Clutch Rear
10 - Front Pump Support Pressure Plate
(Part of 7A 103) 45 377127-S Forward Clutch Pressure
11 20346-S8 Hex Head Bolt 377437-S Plate Retaining Ring
(Part of 7A 103) 377444-S
12 7A103 Front Oil Pump Assembly 386841-2-S
13 70014 Thrust Washer - No.1 46 70090 Forward Clutch Hub Thrust
Washer - No.4
14 7A248 Front Oil Pump Seal -
Large 47 377132-S Retaining Ring
15 70025 Intermediate Brake Drum 48 7B067 Forward Ring Gear Hub
Seal (2 Req'd) 49 70392 Forward Ring Gear
16 7A136 Oil Pump Gasket 50 7A166 Forward Planet Carrier
17 70029 Intermediate Brake Band Thrust Washer - No.5
Strut 51 70236 Forward Clutch Hub Thrust
18 70034 Intermediate Band Race
19 70430 Intermediate Band Anchor 52 70234 Forward Clutch Hub Thrust
Strut Bearing Assembly - No.3
and No.6 (2 Req'd)
53 70235 Forward Clutch Hub Thrust
21 7E056 Direct Clutch Piston Inner Race
Seal
54 7A398 Forward Planet Carrier
22 7A548 Oirect Clutch Piston Outer Assembly
Seal
55 70063 Sun Gear
23 7A262 Direct Clutch Piston
56 377300-S Front Retaining Ring
24 7B488 Oirect Clutch Piston Spring
(10 Req'd) 57 70064 Input Shell
25 7A527 Oirect Clutch Piston Spring 58 70066 Input Shell Thrust Washer
Retainer 59 377300-S Rear Retaining Ring
26 377136-S Direct Clutch Piston Spring 60 377155-S Retaining Ring
Retainer Ring 61 70423 Reverse Planet Carrier
27 7B442 Direct Clutch External Spline Thrust Washer - No.7 and
Plate - (Steel) No.8
28 7B164 Direct Clutch Internal Spline 62 70006 Reverse Planet
Plate - (Friction) 63 387031-S5 Retaining Ring
29 7B066 Direct Clutch Pressure Plate 64 7A153 Output Shaft Ring Gear
30 7C096 Intermediate Brake Orum 65 70164 Output Shaft Hub
Thrust Washer - No.2 66 377132-S Output Shaft Hub Retaining
31 377126-128S Direct Clutch Pressure Plate Ring
377437 Retaining Ring 67 70422 Output Shaft Hub Thrust
377444-S Bearing - No.9
32 70019 Forward Clutch Cylinder 68 7B067 Reverse Clutch Hub
Seal (2 Req'd)
69 7A089 One-Way Clutch Assembly
33 7A360 Forward Clutch Cylinder
70 385044-S Reverse Clutch Retaining
34 7A548 Forward Clutch Piston Outer Ring
Seal
71 7B066 Reverse Clutch Pressure
(Continued) Plate
(Continued)
ALL RIGHTS RESERVED
07·018·5 Transmission, Automatic, C6 07·018·5
Part Part
72 7B164 Reverse Clutch Internal 112 70027 Intermediate Band Servo
Spline Plate - (Friction) Cover
73 7B442 Reverse Clutch External 113 70024 Intermediate Band Servo
Spline Plate - (Steel) Cover Piston Seal
74 7E085 Reverse Clutch Wave Spring 114 70026 Intermediate Band Servo
75 70403 Reverse Clutch Piston Outer Cover Gasket
Seal 115 70021 Intermediate Band Servo
76 70404 Reverse Clutch Piston Inner Piston and Rod Assembly
Seal 116 70028 Intermediate Band Servo
77 - One-Way Clutch Race - Piston Spring
Inner (Part of 70164) 117 70273 Oil Tube Connector
78 70406 Reverse Clutch Retainer and (2 Required)
Spring Assembly 118 87650-S Pipe Plug - 1/8-27 Oryseal
79 70402 Reverse Clutch Piston (Used in Case for Measuring
Throttle Valve Pressure)
80 70167 One-Way Clutch Inner Tag
Attaching Bolt (5 Req'd) 119 7034 Vent
81 7005 Case 120 7E206 Intermediate Band Servo
Lever Shaft Retainer
82 7B368 Output Shaft Thrust Washer
-No. 10 121 70433 Intermediate Band Actuating
Lever Shaft
83 7A233 Output Shaft Park Gear
122 7330 Intermediate Servo Band
84 7C232 Oil Distributor Sleeve
Lever
85 70000 Oil Distributor Tube -Inlet
123 70071 Parking Pawl Shaft
86 70000 Oil Distributor Tube - Outlet
124 7A441 Parking Pawl
87 20386-S8 Bolt (4 Req'd)
125 ·70070 Parking Pawl Return Spring
88 387035-S5 Retaining Ring
126 379058-S Screw and Washer
89 70011 Governor Housing Seal Ring Assembly
(3 Req'd - 2 Teflon@,
127 70419 Park Rod Guide Plate
1 Cast Iron)
(Serviced in Kits Only)
90 70220 Governor Oil Collector Body
128 56119-5 Hex Fig. Head Bolt, 5/ 16-18
91 7C063 Governor x .82 - (7F013, 7F006 and
92 34805-S8 Bolt (4 Req'd) 7A377 ~o 7005)
93 378259 Cup Plug 129 7F013 Vacuum Diaphragm Heat
94 7060 Output Shaft Shield
95 7086 Extension Housing Gasket 130 7A377 Throttle Valve Control
96 7A039 Extension Housing (4x2) Diaphragm
97 7A034 Extension Housing Bushing 131 7F006 Vacuum Diaphragm Clip
98 7052 Extension Housing Oil Seal 132 7A380 Throttle Control Valve Rod
380207-S2 Bolt (2 Req'd) (4x2 Only) 133 70080 Primary Throttle Valve
99
100 7G496 Switch Wiring Harness 134 33798-S8 Nut-5/16
Retainer (4x2) 135 34806-S7 Hex Lock Washer
101 57621-S2 Screw and Washer 136 7A394 Downshift Control Outer
Assembly, 1/4-20 x .62 Lever
102 7H183 Extension Housing Plug 137 55651-52 Screw and Washer
(Used to Plug Speedometer Assembly
Gear Hole) 138 7A247 Park / Neutral Position
103 380209-S Bolt (4 Req'd) (4x2) Switch
104 7G496 Vacuum Tube Retainer 139 386078-S Throttle Control Outer Lever
(4x2) Seal
105 7A039 Extension Housing (4x4) 140 7A256 Manual Control Lever
10~ ?G495 Vacuum Tube Retainer (4x4) 141 78498 Manual Control Lever Oil
107 380209-S Bolt (4 Req'd) (4x4) Seal
108 7G496 Switch Wiring Harness 142 375185-S100 Locknut
Retainer (4x4) 143 7A178 Adjusting Screw
109 58642-52 Bolt (2 Req'd) (4x4 Only) 144 56501-S2 Hex Fig. Bolt, 1/4-20 x .50
110 57633-S2 Bolt (4 Required) 145 7A261 Manual Valve Detent Lever
Spring
111 - Transmission Model
Identification Tag 146 6572 Parking Plate Shaft Plug
(Not Serviced) 147 70418 Parking Plate Shaft
(Continued) 148 70417 Parking Plate Torsion Spring
(Continued)

ALL RIGHTS RESERVED
Part Part
149 70414 Parking Rod Support Plate 162 - Main Control Valve Body
150 87650-S Pipe Plug - 1/8-27 Dryseal Separator Plate
Tapered Thread (Used in Reinforcement
Case for Measuring Pump (Part of 7A 100)
Pressure) 164 7E387 Main Control Pump Inlet
151 70411 Parking Pawl Actuating Rod Screen
(Serviced in Kits Only) 165 - Valve Body Separating Plate
152 70261 Downshift Detent Lever (Part of 7A 100)
153 380525-S Hex Lock Nut, 9/ 16-18 166 70100 Valve Body Separating Plate
154 7A115 Manual Valve Detent Lever Gasket
(Serviced in Kits Only) 167 - Lower Control Valve Body
155 - Shift Valve Plate (Part of 7A 100)
(Not Serviced Separately) 168 7E062 Oil Pan Screen Gasket
156 7326 Gear Selector Valve Rod 169 7A098 Oil Screen
157 70075 Downsh ift Lever Stop 170 357050-S Screw, 1/4-20 x 1.50
(Part of 7A 100) Hex-Head (2 Req'd)
158 - Throttle Pressure Booster 171 7A102 Lower Main Control Valve
Valve Plate (Not Serviced Body Suction Tube
Separately) 172 337051-S Screw, 1/4-20 x 1.40
159 70227 Throttle Pressure Valve Hex-Head (6 Req'd)
Secondary Spacer 173 7A100 Main Control Valve Body
160 - Upper Control Valve Body 174 7A191 Oil Pan Gasket
(Part of 7A 100) 175 7A194 Transmission Oil Pan
161 - Main Control Valve Body - (Shallow - 4x2)
Reinforcement Plate - (Deep - 4x4)
(Part of 7A 100) 176 378782-S Bolt
(Continued) 177 87031 Vacuum Diaphragm a-Ring

ALL RIGHTS RESERVED
C6 Bearing, Bushings and Thrust Washers
D15117·A
Part Part
1 7B258 Front Pump Bushing 10 7A034 Extension Housing Bushing
2 70048 Intermediate Brake Drum 11 7025 Cage Bushing Front / Rear
Front Bushing (Large) 12 70066 Input Shell Thrust Washer
(Part of 70044) 13 70065 SVN Gear Bushing
3 7C096 No.2 Intermediate Brake Front/Rear
Drum Thrust Washer (Part of 70063)
4 70090 No.4 Forward Clutch Hub 14 70235 Bearing Rear Race
Thrust Washer 15 70234 Thrust Bearing
5 7A166 No.5 Planet Carrier Thrust 16 70236 Bearing Front Race
Washer
6 7A166 No.7 Planet Carrier Thrust Rear Bushing (Small)
Washer (4 Tabs -7.5L (Part of 70044)
Only) 4 Pinion
18 70018 Front Pump Support Rear
7 7A166 No.8 Planet Carrier Thrust Bushing
Washer (4 Tabs -7.5L (Part of 7A 103)
Only) 4 Pinion
19 70014 No. 1 Front Pump Support
8 70422 No.9 Output Shaft Hub Thrust Washer
Thrust Bearing
20 7B261 Front Pump Support Front
9 78368 No. 10 Output Shaft Thrust Bushing
Washer (Part of 7A 103)
(Continued)

ALL RIGHTS RESERVED
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CHECK VALVE
INTERMEDIATE SERVO
CAPACITY MODULATOR
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ALL RIGHTS RESERVED
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Transmission Range Selector and Shift Oil Pump

Pattern The oil pump assembly provides a constant supply of
(P) Park fluid under pressure to operate, lubricate and cool the
transmission.
There is no power flow through the transmission in the
park position. The parking pawl locks the output shaft
(7060) to the case, preventing the vehicle from rolling.
The engine can be started in the park range. Also, the
vehicle gearshift lever (7210) must be in the park
Main Control Valve Body
position before the ignition key can be removed. The main control valve body (7A 100) directs fluid
under pressure to the torque converter (7902), band
(R) Reverse servo, clutches and governor to control the
The reverse gear position enables the vehicle to be transmission's operation.
operated in a rearward direction.
(N) Neutral
As in the park position, there is no power flow through Geartrain
the transmission in the neutral position. However, the
vehicle's wheels are free to move because the output The geartrain consists of the following components:
shaft is not held by the parking pawl. The engine may • ring gears
be started in the neutral position, but the key cannot
be removed. • sun gears
(D) Drive • planet pinions and carriers
These components moved into different positions by
Drive is the normal selector position for most driving
hydraulic systems provide the transmission with its
conditions. This position provides automatic upshifts
different gear ratios.
and downshifts through all three gears and maximum
fuel economy during normal operation.
(2) Manual Second
Selection of the second gear position with the vehicle Main Geartrain Components
in a stationary position will allow second gear to Input Shaft
operate only (no upshifting or downshifting will occur).
If (2) position is selected at normal road speed, the The input shaft (7017) transfers motion and torque
transmission will downshift to second gear and stay from the converter turbine to the geartrain. This shaft
there. is splined to the turbine on one end and to the forward
clutch cylinder and stub shaft on the rearward end.
( 1) Manual Low
Compound Planetary Gears
Selection of the manual low position with the vehicle
stationary will allow first gear operation only, and the The planetary gearset consists of forward and output
vehicle will not upshift from this position. If this position shaft gears, pinion carriers, pinions and gears. The
is selected at normal road speed, the transmission will members are driven to produce three forward gears
initially downshift into second gear, then downshift into plus one reverse gear.
first gear when the vehicle speed falls below Output Shaft
approximately 32 km/h (20 mph).
The output shaft (7060) provides a torque to the
The manual low position will provide engine braking, driveshaft and rear axle assembly. It is driven by the
making it especially useful for descending steep output shaft ring gear hub and forward carrier.
grades.

Torque Converter
The torque converter (7902) couples the engine to the
planetary geartrain. It also functions as a torque Troubleshooting the automatic transmission is
multiplication unit. The torque converter consists of the simplified by using proven methods of diagnosis. One
following parts: of the most important things to remember is that there
is a definite procedure to follow. Do not try to short cut
• impeller or take it for granted that someone else has done the
critical checks or adjustments.
• stator
• turbine

ALL RIGHTS RESERVED
The following procedures are recommended for • Noise / vibration - check for dependencies
checking and / or verifying that the various RPM dependent
components are adjusted and operating properly. If
Rotunda Automatic Transmission Tester 014-00737 Vehicle Speed dependent
or equivalent is used, follow the manufacturer's Shift dependent
instructions.
Gear dependent
1. Know and understand the customer's concern
and determine concern relative to vehicle usage. Range dependent
Temperature dependent
• Hot or cold vehicle operating temperature
3. Vehicle at normal operating temperature.
• Hot or cold ambient temperatures
4. Check transmission fluid level and condition.
• Type of terrain Check for contamination or burnt odor. Check for
• Vehicle loaded / unloaded leaks.
• City or highway driving 5. Visually inspect the vehicle for the following
items:
2. Validate customer's concern and know when it
exists. • vehicle modifications
• Upshift • electronic add-on items
• Downshift • leaks
• Coasting • proper linkage adjustments
• Engagement 6. Check Technical Service Bulletins and Oasis for
concern information.
7. Check shift linkage, downshift linkage and
vacuum lines for proper adjustment and
installation.
8. Verify park/neutral position switch is adjusted
properly in neutral.
9. Road test vehicle to confirm customer concern.
Symptom Chart
• Slow Initial Engagement in Either • Improper fluid level. • PERFORM fluid level check.
Forward or Reverse Range • Damaged or improperly adjusted
linkage (shift cable).
• SERVICE or ADJUST linkage from
steering column to transmission.
•• ••
Contaminated fluid. PERFORM fluid condition check.
Improper clutch and band PERFORM line pressure test.
application, or low main control
pressure.
•
•• ••
Rough Initial Engagement in Either Improper fluid level. PERFORM fluid level check.
Forward or Reverse High engine idle. ADJUST idle to specifications.
REFER to the Powertrain
Control/Emissions Diagnosis
1
Manual.
• Looseness in the driveshaft,
U-joints or engine mounts.
• SERVICE as required.
• Improper clutch or band

application, or fluid control
• PERFORM line pressure test.
pressure.
• Sticking or dirty main control valve
body.
• CLEAN, SERVICE or REPLACE
main control valve body.


ALL RIGHTS RESERVED
AUTOMATIC TRANSMISSION (Continued)

• •• ••
Harsh Engagements - Warm Improper fluid level. PERFORM fluid level check.
Engine Engine curb idle too high. CHECK engine curb idle. REFER to
the Powertrain Control/Emissions
Diagnosis Manual. 2
• Main control valve body bolts -
loose / too tight.
• TIGHTEN to specification.
• Main control valve body

dirty / sticking valves.
• DETERMINE source of
contamination. SERVICE as
required.
• No / Delayed Forward Engagement • Improper fluid level. •• PERFORM fluid level check.
(Reverse OK)
• Shift cable and bracket -
misadjusted / damaged.
CHECK and ADJUST or SERVICE
as required.
• Low main control pressure
(leakage). Front clutch support
• PERFORM line pressure test,
NOTE results.
seal rings leaking (No.3, No.4).
• Forward clutch cylinder assembly
burnt / damaged / leaking. Check
• PERFORM air pressure test.
ball in piston / leaking piston seals.

loose / too tight.

required.
• Transmission main control screen
plugged.
• REPLACE transmission main
control screen.
• Front pump support and gears
damaged / leaking.
• Visually INSPECT front pump
support and gears. REPLACE if
necessary.
•
•• ••
No / Delayed Reverse Engagement Improper fluid level. PERFORM fluid level check.
(Forward OK) Shift cable and bracket CHECK and ADJUST or SERVICE
misadjusted I damaged. as required.
• Low main control pressure in
reverse. Reverse clutch drum OK.
• Reverse clutch drum assembly

burnt /worn / leaking. Leaking
check ball in high / reverse clutch

piston / leaking p!ston seals.
loose / too tight.

required.
• Transmission main control screen
plugged.
• REPLACE transmission main
control screen.
• Front pump support and gears
damaged.
• Visually INSPECT front pump
support and gears. REPLACE if
necessary.
• No / Delayed Reverse Engagement

and / or No Engine Braking in ••
Improper fluid level.
Clutch piston seals, leaking.
•• PERFORM fluid level check.
CHECK and REPLACE clutch
Manual Low piston seal.
• Shift cable and bracket
• CHECK and ADJUST or SERVICE
as required.
• No Engine Braking in Manual

Second Gear
• Intermediate band out of
adjustment.
• ADJUST intermediate band.
• Improper band or clutch

application, or fluid pressure
control system.
• Intermediate servo leaking. • PERFORM air pressure test of
intermediate servo for leakage.
SERVICE as required.
•• Polished or glazed band or drum.
Shift cable and bracket
•
•
SERVICE or REPLACE as required.
CHECK and ADJUST or service as
misadjusted / damaged: required.

1995 F-150. F-250. F-350. Bronco, F-Super Duty Powertrain. Drivetrain July 1994

ALL RIGHTS RESERVED

• •
••
Forward Engagement Improper fluid level. PERFORM fluid level check.
Slips / Shudders / Chatters Shift cable and bracket
as required.
•
••
Low main control pressure. PERFORM line pressure test.
Main control valve body bolts -
loose / too tight.

required.
• Front clutch piston ball check not
seating / leaking.
• REPLACE forward clutch piston.
SERVICE transmission as
required.
• Front clutch piston seals cut/worn. • REPLACE seals and SERVICE
one-way clutch as required.
• Low one-way clutch damaged. • DETERMINE cause of condition.
• • ••
Reverse Engagement Improper fluid level. PERFORM fluid level check.
Shudders / Chatters / Slips • Low main control pressure in
reverse.
PERFORM line pressure test.
• Low-reverse clutch / leaking

pressure.
• Air pressure test; visually INSPECT
seal rings and piston bore.
• Clutch piston seals cut / worn. • DETERMINE cause of condition.
• Looseness in the driveshaft,
U-joints or engine mounts.
• No Drive, Slips or Chatters in First

Gear in D. All Other Gears Normal
• Low one-way clutch damaged. • SERVICE or REPLACE one-way
clutch.
• No Drive, Slips or Chatters in
Second Gear
adjustment.

application, or control pressure.
• Damaged or worn intermediate

servo piston seals and / or internal
leaks.
• Dirty or sticking main control valve
body valves.
• Polished, glazed intermediate
band or drum.
• REPLACE or SERVICE as required.
• Starts Up in 2nd or 3rd • Improper band and / or clutch

application, or oil pressure control
system.
• Damaged or worn governor.
Sticking governor primary valve.
• PERFORM governor check.
REPLACE or SERVICE governor.
• Main control valve body bolts
loose.

body valves.
• Cross leaks between main control
valve body and case mating
• SERVICE or REPLACE main control
valve body and / or case as
surface. required.
• •
••
Shift Points Incorrect Improper fluid level. PERFORM fluid level check.
• Improper operation of exhaust gas
recirculation system.
SERVICE or REPLACE as required.

• PERFORM shift test and line
pressure test.
control system.
•
••
Danlaged or worn governor. SERVICE or REPLACE governor.
• Throttle control valve rod
missing / incorrect length or
REPLACE.
throttle valve control diaphragm

assembly bent or leaks.
body valves.
• Vacuum line to transmission
restricted, off or leaking.
• SERVICE or REPLACE vacuum
line.

ALL RIGHTS RESERVED
07-018-13 Transmi~sion,Automatic, C6 07·018·13

• All Upshifts Harsh / Delayed or No
Upshifts
•• Improper fluid level.
Shift cable and bracket -
misadjusted / damaged. as required.
• Governor secondary valve
sticking.
• PERFORM governor test. SERVICE
as required.
• Main control pressure too high. • PERFORM line pressure test.
loose I too tight.

required.
• Vacuum leak to throttle valve
control diaphragm.
• CHECK vacuum lines to diaphragm
unit. SERVICE as necessary.
PERFORM vacuum supply test.
• Downshift cable or downshift
control outer lever damaged / stuck
• REPLACE/REPAIR or ADJUST as
required.
open.
• Mushy/Early All Upshifts/Pile Up
Upshifts
• Low main control pressure. • PERFORM line pressure test. Note
results.
loose / too tight.
• Main control valve body valve or

throttle control valve sticking.
required.
• Governor primary valve sticking. • PERFORM governor test. REPAIR
as required.
• Throttle control valve rod too
short.
• INSTALL correct throttle control
valve rod.
•• ••
• No 1-2 Upshift Improper fluid level.
Shift cable and bracket -
PERFORM fluid level check.
misadjusted / damaged. as required.
• Governor primary valve sticking. • PERFORM governor test. SERVICE
as required.
adjustment.
• Throttle valve control diaphragm

bent, sticking, leaks.
• CHECK throttle valve control
diaphragm. SERVICE as
necessary.
loose I too tight.
• Main con~rol valve body

r
dirty sticking valves.
required.
• Intermediate band burnt and / or
servo assembly leaking.
• Rough / Harsh / Delayed 1-2 Upshift

••
Improper fluid level.
Poor engine performance.
TUNE engine.
adjustment.
• Main control pressure too high. • PERFORM line pressure test.

NOTE results.
as required.
• Engine vacuum leak. Vacuum
line(s) not connected / damaged.
• CHECK engine vacuum lines.
SERVICE as necessary. CHECK
throttle valve control diaphragm.
SERVICE as necessary.
PERFORM vacuum supply and
tests.
loose / too tight.
• TIGHTEN to specifications.

required.

ALL RIGHTS RESERVED
07·018·14 Transmission, Automatic, C6 07-018-14

• Mushy / Early / Soft / Slipping 1-2 • Improper fluid level. • PERFORM fluid level check.
Upshift • Incorrect engine performance. • TUNE adjust engine idle as
required.
adjustment.
• Low main control pressure. • PERFORM line pressure test.

NOTE results.
loose / too tight.

required.
• Damaged intermediate servo or
band.
band or drum.
• SERVICE or REPLACE as required.
• No 2-3 Upshift • Low fluid level. • PERFORM fluid level check.

• Low main control pressure to
direct clutch.
NOTE results.
loose / too tight.

required.
• Direct clutch plates or assembly
burnt /worn. Clutch piston seals
• DETERMINE cause of condition.
damaged.
• Harsh / Delayed 2-3 Upshift • Incorrect engine performance. • CHECK engine tune-up.
• Engine vacuum leak. Vacuum
tine(s) not connected / damaged.
• CHECK engine vacuum lines.
SERVICE as necessary. CHECK
SERVICE as necessary.
PERFORM vacuum supply and
tests.
servo and high clutch piston seals.
• Air pressure test the intermediate
servo. APPLY and RELEASE the
high clutch piston check ball.
loose / too tight.
• Throttle valve control diaphragm or

throttle control valve rod bent,
diaphragm and throttle control
sticking, leaks. valve rod. REPLACE as necessary.
• Soft / Early / Mushy 2-3 Upshift • Main control valve body bolts -
100S9 / too tight.

required.
• Throttle valve control diaphragm or
throttle control valve rod bent,
diaphragm and throttle control
sticking, leaks. valve rod. REPLACE as necessary.
• Erratic Shifts •• Poor engine performance.
Main control valve body bolts - ••
CHECK engine tune-up.
TIGHTEN to specification.
loose / too tight.
NOTE results. DETERMINE source
of contamination. SERVICE as
required.
as required.
• Governor seal rings damaged. • SERVICE as required.

ALL RIGHTS RESERVED

• Shifts 1-3 in D • Intermediate band out of
adjustment.
i
• Damaged intermediate servo
and / or internal leaks.
SERVICE front servo and / or
internal leaks.
system.
band or drum.
• SERVICE or REPLACE
intermediate band or drum.
• Dirty or sticking valve body valves. • CLEAN, SERVICE or REPLACE
valve body.
• Engine Overspeeds on 2-3 Shift • Intermediate band or direct clutch

worn or glazed.
• SERVICE or REPLACE.

control system.
• Intermediate servo piston seal
worn / cut / leaking.
• REPLACE seals. CHECK for leaks.

body valves.
• Rough / Shudder 3-1 Shift at

Closed Throttle in D
• Incorrect engine idle or
performance.
• TUNE, and ADJUST engine idle.
Control/Engine Emissions
Diagnosis Manual. 3
application or fluid pressure
control system.
• Improper governor operation. • PERFORM governor test. SERVICE
as required.
body valves.
• No Forced Downshifts • Downshift control lever or cable

out of adjustment.
• SERVICE or ADJUST cable or
lever.
• Damaged internal kickdown
linkage.
• SERVICE internal kickdown
linkage.
control system.
• Dirty or sticking governor primary
valve.
• PERFORM governor test. SERVICE
or REPLACE governor.
body valves.
• CLEAN, SERVICE, or REPLACE
• Engine Overspeeds on 3-2
Downshift
adjustment.

SERVICE clutch.
system.
servo piston.
• Air pressure test check the
intermediate servo. SERVICE
servo.
••
Polished, glazed band or drum.
Dirty or sticking main control valve
•• SERVICE or REPLACE as required.
CLEAN, SERVICE, or REPLACE
body valves. main ~ontrol valve body.
• Selector Lever Efforts High • Shift cable and bracket

damaged / misadjusted.
as required.
• Inner control manual lever nut
loose.
• TIGHTEN nut to specification.
• Manual lever shaft retaining pin

damaged.
• ADJUST linkage and INSTALL new
manual lever shaft retaining pin.


ALL RIGHTS RESERVED

• Transmission Overheats
••
Improper fluid level. • PERFORM fluid level check.
Incorrect engine idle, or
performance.
• TUNE or ADJUST engine idle.
Control/Engine Emissions
Diagnosis Manual. 4
control system.
• Restriction in transmission fluid
cooler or oil cooler tubes.
• PERFORM cooler flow test.
• Seized converter one-way clutch. • REPLACE one-way clutch.

body valves.
• Transmission Leaks • Case vent. • CHECK the vent for free breathing.
REPAIR as required.
• Leakage at gaskets, seals, plugs,
etc.
• REMOVE all traces of lube on
exposed surfaces of transmission.
OPERATE transmission at normal
temperatures and PERFORM oil
leakage check. SERVIC~ as
required.
• Poor Vehicle Acceleration • Poor engine performance. • CHECK engine tune-up. REFER to
the Powertrain Control/Engine
4
Emissions Diagnosis Manual.
• Torque converter one-way clutch
slipping.
• PERFORM torque converter
checks.
• Transmission Noisy -
Resonance
Valve • Improper fluid level. • PERFORM fluid level check.
REFER to Pinpoint Test A.
•• •
Linkage out of adjustment. SERVICE or ADJUST linkage.
NOTE: Gauges may aggravate any
hydraulic resonance. Remove
Improper band or clutch
gauge and check for resonance control system.
level.
•
•
Oil cooler tubes grounding.
Dirty or sticking ,main control valve
•• RELOCATE oil cooler tubes.
CLEAN, SERVICE or REPLACE
body valves. main control valve body.
• Internal leakage or pump
cavitation.
• Vehicle Will Not Start • Misadjusted park / neutral position

switch.
• ADJUST park / neutral position
switch.
•
••
Misadjusted ignition switch. ADJUST ignition switch.
• Worn or damaged ignition switch. REPLACE ignition switch.
• Worn or damaged park / neutral
position switch.
• REPLACE park / neutral position
switch.
Pinpoint Test
PINPOINT TEST A: TRANSMISSION NOISY - OTHER THAN VALVE RESONANCE

A1 I CHECK GEAR NOISE
•• Check for gear noise to verify if within normal range.
Is noise within normal range?
Yes ~ Normal condition.
No ~ GOtoA2.
A2 I TRANSMISSION SHIFT CABLE AND BRACKET CHECK
• Check shift cable and bracket for proper
adjustment, wear or damage.
Yes ~ GOtoA3.
No ~ SERVICE, REPLACE
• Are shift cable and bracket OK?
and / or ADJUST shift
cable and bracket as
required.


ALL RIGHTS RESERVED
PINPOINT TEST A: TRANSMISSION NOISY - OTHER THAN VALVE RESONANCE (Continued)

A3 I FLUID CHECK
•• Check the fluid for proper level.
Is fluid at proper level?
Yes ~ GOtoA4.
No ~ ADD specified fluid to
bring level between ADD
and FULL marks with
vehicle at operating
temperature. GO to A4.
A4 I STALL TEST
• Perform the Stall Test as described under Stall Test
in the Diagnosis and Testing portion of this section.
Yes ~ GOtoAS.
No ~ EXAMINE torque
• Does noise stop? converter and front pump
assembly. SERVICE or
REPLACE as required.
Also CHECK for loose
torque converter to
flywheel bolts or nuts.
AS I NOISE CHECK
•• Run transmission in all gears and check for noise.
Is noise still present?
Yes ~ SERVICE both planet
assemblies as required.
No ~ Problem not in
transmission. REFER to
Section 00-04 for further
noise diagnosis.
Component Tests Transmission Hot - Operating Temperature

Transmission Fluid Level 1. NOTE: If the vehicle has been operated for an
extended period at high speeds, in city traffic
CAUTION: Your vehicle should not be driven if the during hot weather, or pulling a trailer, the vehicle
fluid level is below the bottom hole on the fluid should be turned off for about 30 minutes to allow
level indicator (7A020) and outside temperatures the fluid to cool before checking.
are above 10°C (500F).
With vehicle on a level surface, start the engine
Ford automatic transmissions use Motorcraft and move the gearshift lever (7210) through all of
MERGON@ Multi-Purpose Automatic Transmission the gear ranges allowing sufficient time for each
Fluid XT-2-QDX or -DDX or equivalent MERGON@ fluid. position to engage. Securely latch the gearshift
Before adding any fluid, be sure that the correct type lever in the park position, fully set the parking
will be used. brake and leave the engine running.
Under normal circumstances, you do not need to 2. Wipe off the oil level indicator cap, pull the fluid
check the fluid level of the transmission, since your level indicator out and wipe the indicator end
vehicle does not use up transmission fluid. However, if clean. Put the fluid level indicator back into the oil
the transmission is not working properly - for filler tube (7A228) and make sure it is fully
instance the transmission may slip or shift slowly, or seated. Pull the fluid level indicator out and read
you may'notice some sign of fluid leakage - the fluid the fluid level.
level should be checked.
It is preferable to check the transmission flui.d level at
normal operating temperature, after approximately 32
km (20 miles) of driving. However, if necessary, you
can check the fluid level without driving to obtain a
normal operating temperature if outside temperatures
are above 10 0 G (50°F).
ALL RIGHTS RESERVED
07-01B-18 Transmission, Automatic, C6 07-01B-18
Transmission Cold - Room Temperature 2. Observe color and odor of the fluid. It should be
When checking fluid at normal operating temperature, dark reddish not brown or black.
the fluid level should be within the crosshatched area • A burnt odor can sometimes indicate that there
on the fluid level indicator. When the vehicle has not is an overheating condition or clutch disc or
been driven, and outside temperature is above 10°C band failure.
(50°F), the fluid level should be between the holes on
the fluid level indicator. 3. Use a clean, lint-free rag to wipe the fluid level
indicator. Examine the stain for evidence of solids
(specks of any kind) and for coolant signs (gum or
varnish on fluid level indicator).
Fluid Level High or Low
A fluid level that is too high will cause the fluid to
FLUID LEVEL AT NORMAL become aerated. Aerated fluid will cause low control
OPERATING TEMPERATURE pressure, and the aerated fluid may be forced out the
66°C TO noc (150°F TO vent (7034).
170°F)
Low fluid level may be the cause of transmission
FLUID LEVEL WHEN slippage or non-engagement. Fluid level may indicate
VEHICLE HAS NOT BEEN fluid leaks that could cause transmission damage.
DRIVEN, AND OUTSIDE
TEMPERATURE Fluid Level High Before Starting Engine, OK
IS ABOVE 10°C (50°F) During Normal Check
D11822-e It is normal for the fluid level to be high prior to the
engine starting. The torque converter will drain due to
Add fluid in .25L (1 /2 pint) increments through the oil the absence of a drainback valve. All clutch
filler tube to bring the level to the correct area on the assemblies of the transmission will drain to the sump
fluid level indicator. If an overfill occurs, excess oil also, causing fluid level to be high.
should be removed by draining. Refer to Transmission
Fluid Dra~n and Refill in this section. Transmission Fluid Leakage Checks
Transmission Fluid Condition Oil Pan
NOTE: Fluid used with the automatic transmission Leakage at the oil pan gasket often can be stopped by
contains a detergent which retains in suspension tightening the attaching bolts to the proper torque. If
particles generated during normal transmission use. necessary, replace the oil pan gasket.
This characteristic may result in a dark coloring of the
fluid and does not by itself indicate malfunction or need
Fluid Filler Tube
for repair. Check the oil filler tube at the case (7005). If leakage
is found, install a new O-ring. The oil filler tube
If specks are present in the fluid or there is evidence of
brackets should align properly and be attached to the
coolant, the transmission oil pan (7A 194) must be
transmission or engine locations.
removed for further inspection. If fluid contamination or
transmission failure is confirmed by further evidence of Transmission Oil Cooler Lines
coolant or excessive solids in the transmission oil pan,
1. Check the oil cooler tubes and fittings on the
the transmission must be disassembled and
transmission and the transmission fluid cooler
completely cleaned and repaired. This includes
(7A095) in the radiator (8005) for looseness,
cleaning the torque converter (7902) (if applicable)
wear or damage. If leakage is found, tighten the
and transmission cooling system. Do not perform any
fitting or replace the damaged parts.
further checks before cleaning and repairing the
transmission.
1. Make the normal fluid check according to the
above procedure.
Torque Limits, Transmission Oil Cooler Tube Fittings
Radiator Transmission 011 Cooler Tube Nut
N·m I Lb-Ft N·m I Lb-Ft N·m I Lb-Ft
11-16 I 8-12 24-31 I 18-23 17-24 I 12-18
ALL RIGHTS RESERVED
2. NOTE: Do not mistake radiator rust inhibitor Fluid Leakage In Torque Converter Area
coating as evidence of transmission oil cooler In diagnosing and correcting fluid leaks in the front
leakage. pump and torque converter area, use the following
Check the engine coolant in the radiator. If procedures to locate the exact cause of the leakage.
transmission fluid is present in the coolant, the Leakage at the front of transmission, evidenced by
transmission fluid cooler in the radiator is fluid around the converter housing, may have several
probably leaking. sources. By careful observation it is possible to
3. WARNING: DO NOT REMOVE A RADIATOR pinpoint the source of the leak before removing the
CAP FROM A HOT COOLING SYSTEM. transmission from the vehicle. The paths which the
ALLOW VEHICLE COOLING SYSTEM TO fluid takes to reach the bottom of the converter
COOL DOWN BEFORE MAKING THE NEXT housing are illustrated.
LEAKAGE CHECK.
Converter Housing Fluid Leaks
Check further for leaks by disconnecting the oil
cooler tubes from the transmission oil cooler
fittings and applying 172-310 kPa (25-45 psi) air
pressure to the fittings. Remove the radiator cap
to relieve the press~re buildup at exterior of the
transmission oil cooler tank. If the transmission
fluid cooler is leaking and / or will not hold
pressure (watch for bubbles through radiator cap
opening), the transmission fluid cooler must be
replaced. Refer to Section 07-02.
4. Replace either or both seals if leakage is found at
either the throttle control outer lever seal or the
manual control lever oil seal (7B498).
Transmission Case
Fluid leakage in the converter housing area may also
be caused by engine oil leaking past the rear main
bearing, from oil galley plugs, power steering oil
leakage from steering system or transmission front oil
pump seal. Be sure to determine the exact cause of
the leak before starting repair procedures.
Oil-soluble aniline or fluorescent dyes premixed at the
rate of 1 /2 teaspoon of dye powder to 0.23 liter (1 /2
pint) of transmission fluid have proved helpful in
locating the source of fluid leakage. Such dyes may be Part
used to determine whether an engine oil or Item Number Description
transmission fluid leak is present, or if the fluid in the
transmission oil cooler leaks into the engine coolant 1 7A248 Front Oil Pump Seal (Large)
system. An ultraviolet lamp must be used to detect the 2 7A136 Oil Pump Gasket
fluorescent dye solution. 3 58619-S2 Bolt
4 - Front Oil Pump Seal
Pipe Plugs (Part of 7A 103)
Inspect the pipe plug on the left front side of the 5 6701 Crankshaft Oil Seal
transmission case. If the plug shows leakage, tighten
the plug to specifications. If leakage continues, Fluid leaking by the front oil pump seal'lip will tend to
replace the plug. Inspect the throttle valve pressure move along the drive hub and onto the back of the
plug on the right rear side of the case. If the plug impeller housing. Except in the case of a total seal
shows leakage install a new drain plug and tighten the failure, fluid leakage by the lip of the large front oil
plug to 9-16 N·m (79-1411b-in). pump seal (7A248) will be deposited on the inside of
the converter housing only, near the outside diameter
When a converter drain plug leaks, remove the drain of the housing.
plug with a six-point wrench. Install a new drain plug.
Tighten the drain plug to 11-37 N·m (8-271b-ft). Fluid leakage by the outside diameter of the large front
oil pump seal and front oil pump body will follow the
same path which the leaks by the large front oil pump
seal follow.
Fluid that leaks by a front oil pump-to-case bolt will be
deposited on the inside of the converter housing only.
Fluid will not be deposited on the back of the torque
converter.
ALL RIGHTS RESERVED
Leakage by the front oil pump-to-case gasket may 4. Start and run the engine until the transmission
cause fluid to be deposited inside the converter reaches its normal operating temperature.
housing, if front oil pump seal allows leakage. Observe the back of the cylinder block and top of
Fluid leakage from the converter drain plugs or the converter housing for evidence of fluid
converter-to-flywheel stud weld will appear at the leakage. Raise the vehicle on a hoist and run the
outside diameter of the torque converter on the back engine at fast idle, then at engine idle,
face of the flywheel (6375), and in the converter occasionally shifting to the drive and reverse
housing only near the flywheel. ranges to increase pressure within the
transmission. Observe the front of the flywheel,
Engine oil leaks are sometimes improperly diagnosed back of the cylinder block (in as far as possible),
as front oil pump seal leaks. The following areas of and inside the converter housing and front of the
possible leakage should also be checked to determine transmission case. Run the engine until fluid
if engine oil leakage is causing the problem: leakage is evident and the probable source of
leakage can be determined.
a. Leakage at the valve cover (6582) or rear intake
manifold gasket may allow oil to flow over the Torque Converter Leakage
converter housing or seep down between the
If welds on the torque converter indicate leakage,
converter housing and cylinder block, causing oil
remove the torque converter and make the following
to be present in or at the bottom of the converter
check.
housing.
Assemble Rotunda Torque Converter Leak Tester
b. Oil galley plug leaks will allow oil to flow down the
021-00054 or equivalent to the torque converter. Test
rear face of the cylinder block to the bottom of
the torque converter for leaks following the directions
the converter housing.
supplied with the tester.
c. Leakage by the crankshaft seal will work back to
the flywheel, and then into the converter housing.
Fluid leakage from other areas, such as the power
steering system forward of the transmission, could Transmission Oil Cooler Flow
cause oil to be present around the converter housing 1. NOTE: The transmission linkage / cable
due to blow back or road draft. The following adjustment, fluid level, and line pressure must be
procedures should be used to determine the cause of within specifications before performing this test.
the leakage before any repairs are made. Refer to In-Vehicle Service in this section.
1. Remove the transmission fluid level indicator and Remove fluid level indicator (7A020) from oil filler
note the color of the fluid. Original factory-fill fluid tube (7A228).
is dyed red to aid in determining if leakage is from
the engine or transmission. Unless a considerable 2. Place funnel in oil filler tube.
amount of makeup fluid has been added or the 3. Raise vehicle on hoist and position suitable safety
fluid has been changed, the color should assist in stands under vehicle.
pinpointing the leak. Since road draft may cause
leaking power steering fluid (also dyed red) to be 4. Remove return oil cooler tube (rear fitting) from
present on the transmission, this leakage, if fitting on transmission case.
present, should be eliminated before checking the 5. Connect one end of a hose to the return oil cooler
transmission for fluid leakage. tube and route the other end of the hose up to a
2. Remove the converter housing cover. Clean off point where it can be inserted into the funnel at
any fluid from the top and bottom of the converter the oil filler tube.
housing, front of the transmission case and rear 6. Remove safety stands and lower vehicle. Insert
face of the engine and engine oil pan. Clean the end of hose into funnel.
converter area by washing with a suitable 7. Start engine and run at idle with transmission in
non-flammable solvent and blow dry with NEUTRAL.
compressed air.
8. When fluid flowing from hose is solid, a liberal
3. Wash out the converter housing, the front of the amount of fluid should be observed. "Liberal" is
flywheel and the converter drain plug. The described as about 1/ 2 quart delivered in 30
converter housing may be washed out using seconds. If a liberal amount is observed, test is
cleaning solvent and a squirt-type oil can. Blow all completed.
washed areas dry with compressed air.
9. If flow is not liberal, stop engine. Disconnect hose
from return oil cooler tube and connect it to the
converter-out line fitting (front fitting) on
transmission case.
1O. Repeat Steps 7 and 8. If flow is now liberal, refer
to Section 07-02 for diagnosis and cleaning of the
transmission oil cooler and tubes. If flow is not
liberal, service front pump assembly and / or the
torque converter assembly.
ALL RIGHTS RESERVED
Engine Idle Speed • Internal hydraulic leakage at the manual shift valve
If the idle speed is too low, the engine will run roughly. can cause delay in engagements and / or slipping
An idle speed that is too high will cause the vehicle to while operating if the external linkage is not
creep, have harsh engagements and harsh correctly adjusted.
closed-throttle downshifts. • Please note that the column-mounted PRNDL is
Refer to the Powertrain Control/Emissions Diagnosis adjustable. Once the transmission shift cable has
Manuals if you suspect an idle problem. been properly adjusted, the PRNDL can be adjusted
to correspond exactly to the transmission shift
On vehicles equipped with an Exhaust Gas cable adjustment.
Recirculation (EGR) system, it is important to check
the system for proper operation and for restricted or Stall Speed Test
leakage conditions. NOTE: The control pressure testing procedure MUST
be performed prior to the following tests.
Shift Linkage
Refer to Specifications in this section for stall speed
Downshift Cable Linkage specifications.
With the accelerator pedal held in the wide-open At the wide-open throttle position, the transmission
throttle position (at the floor), check throttle body downshift outer lever must move to the open position.
lever and linkage travel to be sure they have attained At idle, it must return to the closed position. Refer to
full wide-open throttle. Section 10-02 for the engine throttle linkage
Manual Shift Cable adjustment procedure or replacement procedure.
This is a CRITICAL adjustment. Be sure the D detent in
the transmission corresponds exactly with the D
gatestop in the steering column or console. Refer to
Section 07-05 for adjustment procedures for the shift
indicator cable.


ALL RIGHTS RESERVED
Stall Test Diagnostic Chart
PERFORM LINKAGE CHECK
I I
NOT OK o
t
R_EP_A_IR_A_N_D_IO_R_A_DJ_U_S_T_U_N_KA_G_E_._-...I~WHEN OK
_____ PERFORM FLUID CHECK.
LEVEL NOT OK CONTAMINATED * *
BRING FLUID LEVEL BElWEEN ADD STOPI REMOVE, DISASSEMBLE, CLEAN

AND FULL ON OIL LEVEL INDICATOR AND REPAIR TRANSMISSION. FLUSH OK
I I TORQUE CONVERTER AND
TRANSMISSION OIL COOLER
I
WHEN OK
I t
I ADJUST INTERMEDIATE BAND ce

(AS A MATTER OF NORMAL MAINTENANCE, ADJUSTING THE
,
INTERMEDIATE BAND IS NOT NECESSARY)
I STALL TEST
I
SELECTOR POSITION
STALL SPEEDS HIGH STALL SPEEDS LOW
DONLY FORWARD CLUTCH OR TORQUE CONVERTER STATOR

ONE-WAY CLUTCH ONE-WAY CLUTCH. INCORRECT
TORQUE CONVERTER OR ENGINE
PERFORMANCE
0,2&1 FORWARD CLUTCH OR TORQUE CONVERTER STATOR

ONE-WAY CL~CH ONE-WAY CLUTCH, INCORRECT
TORQUE CONVERTER OR
ENGINE PERFORMANCE
0,2,1& R INCORRECT OR FAILED TORQUE TORQUE CONVERTER STATOR

CONVERTER ONE-WAY CLUTCH, INCORRECT
PERFORMANCE
RONLY REVERSE CLUTCH TORQUE CONVERTER STATOR

ONE-WAY CLUTCH, INCORRECT
PERFORMANCE
* * FOR DEFINmON OF CONTAMINATION SEE rrRANSMISSION FLUID CONDITION CHECK,-IN THIS SECTION D2828-K
Shift Point Road Test Closed Throttle Downshifts

This check will determine if the governor pressure and Check the closed throttle downshift from third to first
shift control valves are functioning properly. by coasting down from about 48 km (30 mph) in third
Check the minimum throttle upshifts in D (drive). The gear. The shift should occur within the limits listed in
transmission should begin in first gear, shift to second, Specifications at the end of this section.
and then shift to third, within the shift points listed in Manual Downshifts
Specifications, at the end of this section.
When the gear selector lever is at 2 (second), the
Forced Downshifts transmission can operate only in second gear.
With the transmission in third gear, depress the With the transmission in third gear and road speed
accelerator pedal through the detent (to the floor). The over 80 km (50 mph) the transmission should shift to
transmission should shift from third to second unless second gear when the gear selector lever is moved
vehicle is traveling above downshift lock-out speed, or from D (drive) to 2 (second) or 1 (first).
third to first (perform at 15-20 mph).

ALL RIGHTS RESERVED
The transmission will downshift from third to second to Refer to the band application chart to aid in diagnosis
first gear when this same manual shift is made below of transmission conditions.
approximately 30 km (18 mph).
C6 AUTOMATIC TRANSMISSION CLUTCH AND BAND APPLICATION SUMMARY

Forward Planetary Gearset Rear Planetary Gearset
Gear Holding Members Driven Held Output Driven Held Output
Forward Clutch
Forward Ring Forward
Manual Low 1 Assembly and Sun Gear Sun Gear Rear Planet Ring Gear
Gear Planet-
Reverse Clutch
Forward Clutch
Forward Ring Forward
DLow Assembly and Sun Gear Sun Gear Rear Planet Ring Gear
Gear Planet-
One-Way Clutch
Forward Clutch
D Second Forward Ring Forward
Assembly and Sun Gear Effectively in Neutral
or2 Gear Planet
Intermediate Band
Forward Clutch
Sun Gear
Assembly and Forward
High Forward Ring None Turns As a Unit
Direct Clutch Planet
Gear
Assembly
Reverse Clutch
Assembly and Rear Planet
Reverse Effectively In Neutral Sun Gear Ring Gear
Direct Clutch Carrier
Assembly
a The front planet carrier is actually turning with the output shaft, but at a slower speed than the input shaft.
Governor 3. Place the transmission in D (drive), no load on the

The governor can be checked at the same time as the engine and apply 10 inches of vacuum to the
Control Pressure Test is performed and in the same throttle valve control diaphragm. Increase the
manner. speed slowly and watch the speedometer. Check
the mph at which the control pressure cutback
1. NOTE: After each test, move the gear shift lever occurs. It should occur between 16-32 km (10-20
to N (neutral) and run the engine at 1000 rpm to mph). .
cool the transmission.
The governor is good if the cutback occurs within
CAUTION: Never exceed 96 km (60 mph) these specifications. If the cutback does not occur
speedometer speed. within specifications, check shift speeds to verify that
NOTE: Connect pump to throttle valve control it is the governor and not a stuck cutback valve, then
diaphragm with a hose long enough to reach up to repair or replace the governor.
the driver's seat. Line Pressure Test
Raise the vehicle with an axle or frame hoist so There are two methods of performing the line pressure
that the rear wheels are clear of the floor. test. One is to perform the test using the engine
2. Disconnect and plug the vacuum line to the vacuum. The second method is to use a remote
throttle valve control diaphragm. Connect vacuum source such as the one provided in the
Vacuum Pump D83L-7059-A or equivalent to the distributor tester or a hand-operated vacuum pump.

ALL RIGHTS RESERVED
Control Pressure Test Diagnostic Chart
r LINE PRESSURE TEST

1
I
LOW AT IDLE
I
HIGH AT IDLE
1
OK AT IDLE
IN ALL rGES INALLjNGES IN ALL RANGES
I
CHECK LOW OIL LEVEL,
RESTRICTED INTAKE
I
LOW AT OKA~10IN.
SCREEN OR FILTER, LOOSE 10 IN. VACUUM BUT LOW
CHECK THROTTLE VALVE AT 1 IN. yACUUM
OIL COOLER TUBES, LOOSE CONTROL DIAPHRAGM VACpUM
MAIN CONTROL VALVE UNIT. MANIFOLD VACUUM
BODY OR REGULATOR TO LINE, OR THROTTLE VALVE THROTTLE VALVE EXCESSIVE LEAKAGE,
CASE BOLTS, EXCESSIVE CONTROL ROD, SnCKlNG CONTROL DIAPHRAGM LOW PUMP CAPACITY
LEAKAGE IN FRONT PUMP, REGULATOR BOOST UNIT OR THROTTLE RESTRICTED OIL PAN
CASE, MAIN CONTROL VALVE(S). VALVE CONTROL ROD. SCREEN.
VALVE BODY OR A SnCKING
CONTROL PRESSURE
REGULATOR VALVE.
I LINE PRESSURE TEST

I
I
LOW IN
I
I
p N
I D
I I
2 1
I I
R
I
MAIN
I
MAIN FORWARD
I I
FORWARD
I
FORWARD
I
REVERSE
CONTROL CONTROL CLUTCH CLUTCH CLUTCH CLUTCH
VALVE BODY VALVE BODY AND/OR AND/OR AND/OR
INTERMEDIATE REVERSE SERVO
SERVO CLUTCH OR
DIRECT
CLUTCH
CD2I36-D
Engine Vacuum Procedure If the shifts do not occur within limits, or the
When the throttle control diaphragm is operating transmission slips during shift point, use the following
properly and the manual and downshift linkage is procedure to determine whether the engine,
adjusted properly, all the transmission shifts transmission, linkage, throttle valve control diaphragm
(automatic and kickdown) should occur within the road or main control valve body (7A 100) is causing the
speed limits listed in Specifications at the end of this condition.
section.

ALL RIGHTS RESERVED
1. CAUTION: Pressure gauges affect the shift 4. If the engine idle speed is not within
quality of the transmission. Care should be specifications, refer to the Powertrain
taken NOT to accelerate or decelerate Control/Emissions Diagnosis Manuals for repair
rapidly. Possible transmission failure could procedures. Also check throttle and downshift
result. linkages for binding conditions.
Attach a tachometer to the engine and a Rotunda • If linkage is satisfactory, check for vacuum
Vacuum / Pressure Tester 059-00008 or leaks in the throttle valve control diaphragm
equivalent to the transmission vacuum line at the and its connecting tubes and hoses. Check all
manifold vacuum port. other vacuum-operated units (such as the
power brake) for vacuum leaks. Refer to the
appropriate brake section in Group 06.
MANIFOLD VACUUM
LINE HOSE Vacuum Pump Procedure
T-FITTING 1. Disconnect and temporarily plug the vacuum line
at the throttle valve control diaphragm. Attach a
vacuum pump to the throttle valve control
diaphragm.
2. Apply both the parking and service brakes. Start
the engine and vacuum pump.
3. Set the vacuum at 15 inches, read and record the
line pressure in all manual control lever positions.
Run the engine up to 1000 rpm, and reduce the
vacuum to 10 inches. Read and record the line
pressure in D, 2 and 1. Keep the engine rpm at
1000 and reduce the vacuum to 1 inch. Read and
record the line pressure in D, 1,2 and R.
TO ROTUNDA VACUUM/
PRESSURE TESTER 4. Refer to the Control Pressure Test Diagnostic
059-00008 Chart to show what components are inoperative
when the line pressure test is not within
THROTTLE VALVE specifications. Do not proceed until you have
DIAPHRAGM CONNECTION made any repairs, as required, and the control
D7388-C
pressure is within specifications as listed in
2. Attach a pressure gauge to the line pressure Specifications, at the end of this section.
outlet at the transmission.
Vacuum Supply Test
The vacuum supply to the throttle valve control
diaphragm and the diaphragm itself must be checked.
1. Disconnect the vacuum line at the throttle valve
control diaphragm and connect it to a vacuum
gauge. With the engine idling, the gauge must
have a steady acceptable vacuum reading for the
altitude at which the test is being performed.
• If the vacuum reading is low, check for a
vacuum leak. If the vacuum reading is OK,
rapidly accelerate the engine momentarily
while applying the service brake and with the
transmission in PARK. The vacuum reading
must drop rapidly at acceleration and return
immediately upon release of the accelerator. If
the vacuum reading does not change or
07390-8 changes slowly, the transmission vacuum line
is plugged, restricted or connected to a
3. Firmly apply the parking brake and start the reservoir supply.
engine.


ALL RIGHTS RESERVED
2. Correct as required. 2. Connect the vacuum hose to the manifold vacuum

port as shown previously. If the gauge still reads
18 inches, the throttle valve control diaphragm is
not leaking. A second leakage check can be
made as the hose is removed from the
transmission. Hold a finger over the end of the
control rod. When the hose is removed, the
internal spring of the vacuum unit should push the
throttle control valve rod (7A380) outward. If the
vacuum diaphragm needs replacing, install a new
unit modulator assembly that has been released
for service. Reinstall the vacuum throttle valve
diaphragm heat shield. Throttle valve control
diaphragm assembly identification is given at end
of this section.
Air Pressure Tests
Refer to the control pressure test diagnostic chart to
show what components are inoperative when the NOTE: When you have a slip problem and do not know
control pressure test is not within specifications. Do whether it is in the main control valve body or in the
not proceed until you have made any required repairs, hydraulic system beyond the main control valve body,
and the control pressure is within specifications as the air pressure tests can be very valuable.
listed in Specifications at the end of this section. To make the air pressure checks, loosen the
Vacuum Diaphragm Test On-Vehicle transmission oil pan bolts and lower one edge to drain
the transmission fluid. Remove the transmission oil pan
1. NOTE: If automatic transmission fluid is present in (7A 194) and the main control valve body. The
the vacuum side of the throttle valve control inoperative clutches or bands can be located by
diaphragm or in the vacuum hose, the throttle introducing air pressure into the various transmission
valve control diaphragm is leaking and must be case passages.
replaced.
A no-drive condition can exist, even with correct
To check the throttle valve control diaphragm, transmission fluid pressure, because of inoperative
start the vacuum pump and set the regulator knob clutches or bands. An erratic shift can be caused by a
so that the vacuum gauge reads 18 inches with stuck governor primary valve. The inoperative units
the end of the vacuum hose blocked off. can be located through a series of checks by
2. Connect the vacuum hose to the throttle valve substituting air pressure for fluid pressure to determine
control diaphragm. If the gauge still reads 18 the location of the malfunction.
inches, the throttle valve control diaphragm is not When the gearshift lever (7210) is at D (drive), 2
leaking. If the reading does not remain at 18 (second) or L (low) a no-drive condition may be
inches, but drops, the throttle valve control caused by an inoperative forward clutch or one-way
diaphragm is leaking. Remove vacuum throttle clutch. Failure to drive in R (reverse) could be caused
valve diaphragm heat shield and replace the by a malfunction of the reverse clutch.
throttle valve control diaphragm. Reinstall throttle
valve control diaphragm heat shield.
Vacuum Diaphragm Test Off-Vehicle
1. To check the throttle valve control diaphragm for
diaphragm leakage, remove the unit from the
transmission. Use a distributor tester equipped
with Rotunda Vacuum Tester 021-00014 or
equivalent vacuum pump. Set the regulator knob
until the vacuum gauge reads 18 inches with the
end of the vacuum hose blocked off.

ALL RIGHTS RESERVED
Case Fluid Passage Hole Identification Reverse Clutch

Apply air pressure to the reverse clutch apply. A dull
thud indicates that the reverse clutch piston (70402)
has moved to the applied position. If no noise is heard,
place the fingertips on the case at reverse clutch and
again apply air pressure to detect movement of the
reverse clutch piston.
Forward Clutch
Apply air pressure to the transmission case front
clutch cylinder passages. A dull thud can be heard
when the forward clutch piston is applied. If no noise is
heard, place the fingertips on the input shell and again
apply air pressure to the front clutch cylinder passage.
Movement of the forward clutch piston can be felt as
the clutch is applied.
Governor
Apply air pressure to the control pressure to governor
passage and listen for a sharp clicking or whistling
noise. The noise indicates governor primary valve
movement.
Intermediate Servo
Hold the air nozzle in the intermediate servo apply
passage. Operation of the servo is indicated by a
tightening of the front intermediate band around the
intermediate brake drum. Continue to apply air
pressure to the servo apply or passage, and introduce
air pressure into the intermediate servo release
passage. The intermediate servo should release the
intermediate band against the apply pressure.
IN-VEHICLE SERVICE
D7392·C
Part Oil Cooler Lines

Item Number Description When fluid leakage is found from the transmission fluid
1 - Servo Apply (Part of 7005)
cooler (7A095), it must be replaced. Refer to Section
07-02.
2 - Servo Release
(Part of 7005) • When one or more of the steel transmission oil
3 - Pump Suction (Part of 7005) cooler tubes (7A031) must be replaced, each
4 - Direct Clutch Apply replacement tube must be fabricated from the same
(Part of 7005) size steel tubing as the original oil cooler tube.
5 - Forward Clutch Cylinder
• Using the old oil cooler tube as a guide, bend the
Apply (Part of 7005)
new tube as required. Add the necessary fittings,
6 - Torque Converter Charge
and install the tube.
(Part of 7005)
7 - Pump Discharge • After the fittings have been tightened, add fluid as
(Part of 7005) needed, and check for leaks.
8 - Reverse Clutch Apply
(Part of 7005)
9 - Control Pressure to
Governor (Part of 7005) Main Control Valve Body
10 - Governor Pressure Output
(Part of 7005) Removal
11 - Exhaust (Part of 7005) 1. Raise the vehicle on a hoist and position safety
12 - Throttle Valve Pressure stands under vehicle.
(Part of 7005)
2. Place a drain pan under the transmission and
13 - Line Pressure (Part of 7005)
loosen the bolts holding the transmission oil pan
14 - Throttle Valve Pressure (7A 194) to drain the fluid from the transmission.
(Part of 7005)
3. Remove the attaching bolts, the transmission oil
pan and oil pan gasket.

ALL RIGHTS RESERVED
4. Remove the main control valve body attaching

bolts and remove the main control valve body Part
(7A 100) from the case (7005). Item Number Description
4 7D021 Intermediate Band Servo
Installation Piston and Rod Assembly
1. Position the main control valve body to the case 5 70026 Intermediate Band Servo
making sure that the gear selector valve rod and Cover Gasket
downshift detent lever (70261) are engaged. 6 70027 Intermediate Band Servo
Install and tighten the attaching bolts to 11-14 Cover
N·m (95-125Ib-in). 7 70024 Intermediate Band Servo
2. NOTE: Do not grind or sand surfaces. Use a Cover Seal
gasket scraper or wir

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Group Index INTRODUCTION

Group 00 SERVICE INFORMATION

ENGINE AND TRANSMISSION

Table -of Group 05 DRIVELINE

Group 09 EXHAUST SYSTEM

IAII rights reserved. Reproduction by any

DAVE GRAHAM INC. - 2014

Notes, Cautions, and Warnings

• Always wear safety glasses for eye protection.

DAVE GRAHAM INC. - 2014

DAVE GRAHAM INC. - 2014

SUBJECTS COVERED IN THIS MANUAL 1

HOW THIS MANUAL IS ORGANIZED ~.~, ~ ~................................. 1

HOW TO FIND MATERIAL IN THIS MANUAL : 3

HOW TO USE EACH SECTION '......................... 3

WHAT TO DO IF YOU DISCOVER AN ERROR 4

DAVE GRAHAM INC. - 2014

• Engine Controls and Diagnosis

How This Manual is Organized

SECTION TITLE PAGE

NOTE: A Group usually contains more than one Section.

DAVE GRAHAM INC. - 2014

DIAGNOSIS AND TESTING

DAVE GRAHAM INC. - 2014

ear shitt lever

How to Find Material in This Manual

How to Use Each Section

DAVE GRAHAM INC. - 2014

What to Do if You Discover an Error

DAVE GRAHAM INC. - 2014

SECTION 00-01 Identification Codes

DESCRIPTION AND OPERATION

DESCRIPTION AND OPERATION (Continued)

I vehicle identification number (VIN).

POSITIONS 1,2 AND 3 - MANUFACTURER, MAKE AND TYPE

DESCRIPTION AND OPERATION (Continued)

UNITED STATES BUILT u.S. BUILT, QUEBEC SALES

CE YBlCULE EST CONFORME ATOUTES LES NORMES FEDERALES DE SECURITE

INCOMPLETE VEHICLES (CANADA) INCOMPLETE VEHICLES (U.S.)

INCOMPLETE VEHICLE MANUFACTURED BY FORD MOTOR CO. OF INCOMPLETE VEHICLE MANUFACTURED BY

YIN: 2FDKF37M6LCAOOOO8 VIN: 1FDKF37MOLKAOOOO5

W7401 111111111111111111111 881067 yy

DESCRIPTION AND OPERATION (Continued)

Certification Label Codes

MFD. BY FORD MOTOR CO. IN U.S.A.

:::TRUCK (~/(r(t) \~\~ FOO83

DESCRIPTION AND OPERATION (Continued)

Yellow ink is normally used for the date stamp. When

VEHICLE IDENTIFICATION NUMBER

World Manufacturer Identifier

VIN POsmoNS 1, 2 AND 3

Brake System and GVWR Class

1FT ~ F25 H 5 S L AOOOO1

DAVE GRAHAM INC. - 2014

VEHICLE IDENTIFICATION NUMBER (Continued)

Model or Line, Series, Chassis, Cab or Body Type

YIN POSmONS 5, 8 AND 7

1FT EI F2SIH S S L AOOOO1

Engine Type, Displacement, Cylinders, Fuel and Manufacturer