Repair and Diagnosis: Technical Service Bulletins
- How to Find Technical Service Bulletins by Category/Symptom
- Recalls
- Customer Interest
- A/C - Musty Odor Coming From Vents
- Front Brakes - Premature Lining Wear/Hard Pedal
- Brakes - Soft Pedal Feel/Pull/Irregular Wear
- Heater Core - Failure/Leaks At Inlet Tube
- Steering Gear - Leak At the Input Shaft
- Cylinder Head - Coolant Leak
- Engine - Cooling Concerns and/or Vibration
- Drive Belt - Early Wear of Tensioner Pulley
- Accessory Drive Belt - Chirp or Squeal Noise
- Accessory Drive Belt - Noise/Excessive Wear
- Blower Motor - Inoperative
- Wheel - Mounting Surface Distorted Lug/Pilot Holes
- Front Door Window - Jams In Full Up Position
- A/T - E4OD Overheating and/or Internal Damage
- A/T - E4OD Delayed Initial Gear Engagement
- A/T - E40D Delayed Initial Engagement
- A/T - Torque Converter Access Plug Dislodges
- A/T - AOD Harsh/Rough Shifts
- M/T Clutch Housing - Fluid Inside
- A/T - Harsh Shifts/Trouble Code 62/TCIL Lamp Flashes
- Front Brake Caliper - Piston Boots Damaged
- Brake Pedal - Excessive Travel or Pedal Fade
- Brakes - Sticking/Binding/Grabbing
- Battery - No Engine Crank/Low Battery Charge
- Alternator - Discharge
- Instrument Cluster Warning Lights - Dimly Lit
- Speed Control - Intermittent or Inoperative
- A/C Compressor Shaft Seal - Leaks
- Brakes - False or Dropping Pedal
- Ignition Switch - Key Hard To Rotate When Cold
- Body/Frame - Water Leak Identification and Correction
- Roof Support Bows - Rattle Against Roof Panel
- Engine - Hard Starting/Long Cranking Time
- Instrument Panel - Creaking/Squeaking Noise
- Wheel Cover - Centers Damaged By Stones
- A/T - Harsh 3rd to 4th Gear Upshift
- A/T - AOD Delayed Shift Times
- A/T - E40D Harsh 3rd to 4th Gear Upshift
- Accessory Drive Belt - Broken/Damaged
- A/T - E4OD Shift Concerns/DTC's Set
- Speed Control - Abnormal Operation When Hot
- Engine - Stalls When Coming to A Stop
- A/T - AOD Buzzing At Idle/Grunting During Tip-In
- Exhaust System - Excessive Heat On Cargo Floor
- M/T - M50D Hard Shift Condition
- M/T - Crunching Shifting From 2nd to 3rd Gear
- A/T - E40D Clunk Shifting to Drive or Reverse
- A/T - Harsh/Delayed 1st - 2nd and 2nd - 3rd Gear Shifts
- Defroster - Inadequate Output On Passenger Side
- Labor/Parts Updates
- Seals, Gaskets
- Superceded Bulletins
- 9156 - 03/06/91
- 91118 - 05/30/91
- 90819 - 04/11/90
- 902612 - 12/19/90
- 902517 - 12/07/90
- 902411 - 11/21/90
- 90148 - 07/05/90
- 90128 - 06/07/90
- 90119 - 05/23/90
- 89311 - 02/08/89
- 882613 - 12/21/88
- 881710 - 08/17/88
- 87812 - 04/24/87
- 87716 - 04/08/87
- 861116 - 06/05/86
- 841915 - 09/12/84
- 831915 - 09/20/83
- Frame Rivets - Damaged/Loose
- Running Boards - Installation Precautions
- A/C - Identification Of Non Approved Refrigerants
- A/C - R134A Retrofit Kit Availability
- A/C - R12 to R134a Retrofit Kit Availability
- A/C - Approved Flushing Procedures
- Air Conditioning - Musty or Mildew Type Odors
- A/C System - Musty/Mildew Odors
- A/C - O Ring Removal From Spring Lock Coupling
- Frame - Rivet Replacement With Bolts, Service Tip
- Frame - Damaged or Loose Rivets
- Power Steering Gear - Leak Fluid At the Input Shaft
- Wire Splicing And Wire Harness- Terminal Repair Kit
- Wire Harness - Terminal Repair Kit/Wire Splice Procedure
- Wire Harness - Terminal Repair And Wire Splice Kit
- Wire Harness - Terminal Repair Kit/Wire Splice Repair
- Wire Harness - Terminal Repair Kit/Splice Procedure
- Electrical - Wiring Harness Terminal Repair Kit
- Wire Harness - Terminal Repair Kits
- Wire Harness Terminal and Connector - Repair Kit
- Wire Harness - New Terminal Repair Kit
- Ignition Cylinder - Key Hard to Turn When Cold
- Charging - Generator Discharge/Damaged Connector
- Front Brakes - Stick/Bind/Grab
- Brakes - Irregular Pad Wear/Soft Pedal/Pull
- Front Caliper Piston Boots - Damaged
- A/T - E4OD Updated Parts Installation
- A/T - New Transmission Cooler Flusher/Service Tip
- A/T - E4OD MIL ON/Codes 62/628/1728 Set
- A/T - E4OD Internal Parts Usage Chart
- A/T - E4OD Parts Usage Chart
- A/T - E4OD Internal Part Usage Chart
- A/T - E40D Upgrade Components During Overhaul
- A/T- E4OD/4R100 Parts Usage Chart
- Torque Converter - Metal To Metal Sound
- A/T - E4OD Clunk During Gear Engagement
- A/T - E4OD Internal Part Usage Table
- A/T - E4OD Accumulator Body Usage Chart
- A/T - 3/4 Shift Accumulator Application
- Fuel Pump - Whine/Buzz Noise Heard In Speakers
- Stumble/Rough Idle Install Deposit Resistant Injectors
- A/T - E4OD MIL ON/DTC's 62/628/1728 Set
- A/T - E4OD Overheating
- Exhaust System - Buzzing/Rattling Noises
- Exhaust System - Rattling/Buzzing Noise
- Exhaust System - Buzz/Rattle Noise
- Heater Core - Repeated Failure
- Cooling System - Diagnosis Procedure
- A/T - Fluid Application Charts
- A/C System - New A/C Filter Kit
- A/C - New Filter to Prevent Compressor Damage
- A/C System - New Filter Kit
- Air Conditioning - Prevent Damage to Compressor
- A/C - Refrigerant Filtering Tips
- A/C - Refrigerant Filtering Service Tips
- A/C System - Refrigerant Filtering Service Tips
- Accessory Drive Belt - Squeal/Chirp Noise
- Wheels - Proper Lug Torque Procedures
- A/T - E4OD/4R100 Fluid In-Line Filter Kit
- Propylene Glycol Coolant - Recommendations
- Recycled Engine Coolant - Service Tip
- A/T - Transmission Fluid Usage Charts
- Automatic Transmission - Fluid Usage Charts
- A/C - Filter Kit Installation After Replacing Compressor
- A/C Compressor Replacement - Refrigerant Filtering
- A/C System - Use of R12 Refrigerant Substitutes
- Air Conditioning - Filtering Refrigerant
- A/C - Non Approved Refrigerants
- A/C - Approved/Alternate Refrigerants
- A/C - Identification of Non-Approved Refrigerants
- A/C - Identifying Non-Approved Refrigerants
- All Technical Service Bulletins
- Ford RTV Sealer - Shelf Life
- A/C - Musty Odor Coming From Vents
- A/C System - Service TSB List
- Air Conditioning - R12 to R134A Retrofit Kit
- Air Conditioning - Return of Obsolete Filter Kits
- A/C - Filtering Refrigerant After Compressor Replacement
- Adhesives and Sealants - Availability and Usage
- Diesel Engine Torque Limits - Revision
- Engine Gasket Surface - Cleaning Procedures
- Cooling system - Coolant Water/Anti-Freeze Ratio
- Diesel Engine - Cavitation Errosion Prevention
- Electrical - New Terminal Grease Released For Service
- Fuel Injection Pump - TPS Sensor Service
- Injection Pump Lever Sensor - Specifications Revision
- Fuel Pump/Sender - Defective Parts Return
- Front Brakes - Premature Lining Wear/Hard Pedal
- Brakes - Soft Pedal Feel/Pull/Irregular Wear
- Brakes - Intermittent Brake Squeal
- A/C Compressor - Oil Recovery/Measuring Procedures
- A/C Compressor - Oil Recovery and Measuring Procedure
- A/C Clutch - Slips At High Ambient Temperature
- Air Conditioning - Approved Flushing Procedures
- Heater Core - Failure/Leaks At Inlet Tube
- Heater Core - Core Leak Test Procedure
- Steering Gear - Leak At the Input Shaft
- Cylinder Head - Coolant Leak
- Engine - Coolant in Oil/Knocking/Poor Performance
- Valve Stem Oil Shield - Eliminated
- Cooling System - New System Diagnostics
- Engine - Cooling Concerns and/or Vibration
- Cooling Fan Clutch - Loose/Rattles
- Blade Fan Assembly - Part Return
- Drive Belt - Early Wear of Tensioner Pulley
- Accessory Drive Belt - Chirp or Squeal Noise
- Accessory Drive Belt - Noise/Excessive Wear
- Blower Motor - Inoperative
- Oil Cooler Bundle - Debris Inside
- Wheel - Mounting Surface Distorted Lug/Pilot Holes
- Power Steering - Cooler Kit Availability
- Tires - Best Pressure For Load Application
- Wheel Lug Nut - Torque Specification Revision
- Lug Nuts - Proper Installation/Torqueing Procedure
- Frame - Rivet Replacement with Bolts Service Tip
- Front Door Window - Jams In Full Up Position
- Driveline - Modification Guidelines
- Overview
- Guidelines For Modifying Light Truck Drivelines
- Guideline - Driveline Balance
- Guideline - Runout Limits For an Unbalanced Driveshaft
- Coupling Shaft & Driveshaft Diameters, and Sizing
- Guideline - Driveline Angles
- Driveline Component Phasing
- List of "Things-Gone-Wrong"
- Further Discussion
- Multiple Driveshafts and System Balancing
- General Comments
- References
- A/T - E4OD Main Regulator Booster Service Tip
- A/T - E4OD Overheating and/or Internal Damage
- Torque Converter - Cleaning and Replacement Guidelines
- A/T - E4OD Delayed Initial Gear Engagement
- A/T - E40D Delayed Initial Engagement
- A/T Torque Converter - Leak Test Procedure
- A/T - Torque Converter Access Plug Dislodges
- A/T - AOD Harsh/Rough Shifts
- Engine - Performance Poor Diagnostics
- M/T Clutch Housing - Fluid Inside
- Engine - Rough Idle or Stumble
- Body/Frame - Arc Welding Precautions
- A/T - Harsh Shifts/Trouble Code 62/TCIL Lamp Flashes
- Front Brake Caliper - Piston Boots Damaged
- Brake Pedal - Excessive Travel or Pedal Fade
- Brakes - Sticking/Binding/Grabbing
- Battery - Test Procedure
- Battery - No Engine Crank/Low Battery Charge
- Leece Neville Alternator - Parts Information
- Alternator Service Procedures - Manual Revision
- Alternator - Discharge
- Instrument Cluster Warning Lights - Dimly Lit
- Accelerator Cable - Service Procedures/Tips
- Campaign - Warranty Coverage for Transmission Processor
- Speed Control - Intermittent or Inoperative
- Round Corner Radio Bezel - Removal Holes Nonfunctional
- Audio Systems - Authorized Service Centers
- Starter Motor Brushes - Replacement Revision
- Fuel Tank Sending Unit - Connector Replacement
- Speedometer/Odometer - Inaccurate Readings
- A/C Compressor Shaft Seal - Leaks
- Diesel Engine - Shop Manual Correction
- Brakes - False or Dropping Pedal
- Ignition Switch - Key Hard To Rotate When Cold
- Body/Frame - Water Leak Identification and Correction
- Roof Support Bows - Rattle Against Roof Panel
- Emission Control System - Technician's Glossary
- Optional EEC IV Monitor Requires Update Kit
- Octane Shorting Bar - Manual Revision
- A/T - E4OD TCIL Flashing/DTC's 62/628/1728 Stored
- Electrical/Electronic/Fuel Induction - Glossary
- Engine - Hard Starting/Long Cranking Time
- Door Latches - Adjustment/Modification Prohibition
- Instrument Panel - Creaking/Squeaking Noise
- Windshield/Interior Glass - Fog/Film
- Glass - Iridescence or Mottling In Tempered Glass
- Mirrors - Optional Right Side Mirror Head
- Motor Oil - Viscosity Grade Recommendation
- Cooling System - Proper Fluid Concentrations
- Engine Coolant - Recycled Coolant Not Authorized
- Recycled Engine Coolant - Service Tips
- Engine Coolant - Propylene Glycol Recommendations
- Power Steering Pressure Line - Longer Design
- Brake Hoses - Wet Appearance
- Wheel Cover - Centers Damaged By Stones
- A/T - Harsh 3rd to 4th Gear Upshift
- A/T - AOD Delayed Shift Times
- A/T - E40D Harsh 3rd to 4th Gear Upshift
- A/T - E4OD/C6 Low One-Way Clutch Service Tips
- A/T - E4OD Intermediate Brake Drum Assembly Service Tip
- A/T - E4OD Direct Clutch Plate Usage Chart/Service Tip
- A/T - E40D Overdrive One Way Clutch Tips
- A/T - E4OD Reverse Clutch Piston and Seal Usage
- A/T - AOD Diagnostic Information
- Automatic Transmission Service - Manual Revision
- A/T - E4OD Upgraded Transmission Components
- Overview
- Symptoms/Upgrades
- Overheating, Discoloration, Burned Clutches and Fluid
- Other Upgraded Components
- Case Bushing Wear and Sun Gear Bushing Wear
- Forward Clutch Spline Wear
- Failure Mode Effects Management (FMEM) Enhancements
- FIPL/TP Installation and Adjustments
- Aux. Oil Cooler Install Procedure 89-92 F-Series 7.3L Diesel
- 89-91 E-Series 7.3 Diesel 48 Plate Aux. Oil Cooler Installation
- 1992 E-Series 7.3 Diesel Aux. Oil Cooler Installation
- Front and Rear Case Bushings Removal & Installation
- Low One-Way Clutch Removal and Installation
- Warranty Information
- A/T - E4OD Description and Operation
- A/T - E40D New 4-Speed A/T Description
- A/T - E40D Adhesive Repair Kit Availability
- A/T - E40D/ATX Transmission Exchange Program
- A/T - E4OD Upgrade Ball Bearing Center Support Kit
- A/T - E4OD Electrical Wiring Information
- A/T - E4OD Service Tips
- Overview
- General Description
- E40D Sensors and Actuators
- Processor - Electronic Control Assembly (ECA)
- Inputs
- Vehicle Speed Sensor (VSS)
- Transmission Oil Temperature (Tot) Sensor
- Manual Lever Position (MLP) Sensor
- Brake On/Off Switch (BOO)
- RPM Sensor
- Air Conditioning Clutch
- Barometric and Absolute Pressure Sensor
- Fuel Injection Pump Lever and Throttle Position Sensor
- Overdrive Cancel Switch and Indicator Light
- Low Range Switch - 4 X 4
- Outputs
- Diagnosis and Servicing
- E40D Self Test Overview
- Pinpoint Tests
- E40D Test Harness T89T-70100-A
- Error Codes For Pinpoint Test
- Service Codes:49, 59 and 69 - Pinpoint Test AA
- Service Codes:56 and 66 - Pinpoint Test BB
- Service Code:62 - Pinpoint Test cc
- Service Code:67 - Pinpoint Test Ee
- Service Codes:91, 92, 93 and 94 - Pinpoint Test GG
- Service Codes:98 and 99 - Pinpoint Test Hh
- Error Code Description
- Error Code - Symptoms
- A/T - E4OD Service Specifications/Preautions Revision
- A/T - E40D Delayed Forward Engagement
- A/T - New Rotunda Fluid Changer Service Tip
- A/T - Electronics Diagnostic and Repair Chart
- A/T - Electronic Transmission Repair Process Chart
- A/T - Transmission Flush and Fill Tool Available
- A/T - Check Ball Locations And Function
- A/T - E40D No Second Gear
- A/T - Harsh Reverse Engagements
- A/T - Engine Vacuum Testing
- A/T - E40D Delayed Engagement Forward and Reverse
- A/T - E40D Quick Tests
- A/T - Delayed Engagement In Reverse and Drive
- A/T - C6 Early Shifts, Stacked Shifts, No Upshifts
- A/T - How To Use A Pressure Gauge
- A/T - E40D Burned Overdrive Section
- A/T - Buzzing Noise/Missing Cup Plugs
- A/T - EEC Trouble Codes
- A/T - Diagnostic Trouble Codes for 1983-1992
- A/T - E40D Overdrive Sprag Rotation and Installation
- A/T - E40D Rebuild Tips
- A/T - E40D Check Ball Locations
- A/T - E40D Case Damage During Pump Removal
- A/T - E40D Indexing Manual Valve After Rebuild
- A/T - E40D Case, Separator Plate, and Valve Body I.D.
- A/T - Intermittent Electrical Problems
- A/T - E40D Intermediate Sprag Rotation
- A/T - E40D Front Seal Blow Out
- A/T - E40D Bellhousing Leaks
- A/T - E40D Overdrive Planetary Failure
- A/T - E40D FIPL Sensor Trouble Shooting and Adjustment
- A/T - Failsafe Modes
- A/T - E40D No Converter Engage, 2nd and 4th Gear Starts
- A/T - Cycling or No TCC, Shift Hunting
- A/T - Preventing Front Planetary Gear Failure
- A/T - E40D Extension Housing Bushing Failure
- A/T - E40D No Upshifts or Harsh Upshifts/4th Gear Starts
- A/T - E40D Delayed Engagements
- A/T - E40D Overdrive OFF Light Cycles with Brake Pedal
- A/T - E40D Vibration When TCC is Applied
- A/T - E40D Identifying Latest Controller Assembly
- A/T - E40D ATF Leaking Out Vent
- A/T - E40D Pump Upgrade
- A/T - E40D Pump Modifications
- A/T - E40D No Forward Engagement In O/D, 4-3 Flare Up
- A/T - Delayed Engagement, Shift Errors, MLPS Codes
- A/T - E40D New Solenoid Bodies
- A/T - E40D Intermediate Servo Piston Redesigned
- A/T - E40D No Cooler Flow
- A/T - Slipping or No-Shift/Metal Sealing Rings
- A/T - Front Bushing Wear
- A/T - C6 No. 9 Thrust Washer Failure
- A/T - Math Formulas Part I
- A/T - Twenty Steps To Successful Repairs
- A/T - E4OD Description
- A/T - Math Part II
- A/T - Choosing the Right ATF
- M/T -M5OD HD Troubleshooting Guide
- Recall 90V101000: A/T Extension Housing Replacement
- Accessory Drive Belt - Broken/Damaged
- Drive Belt - V Belt to Serpentine Belt Conversion
- A/T - Mercon V ATF Usage
- A/T - E4OD Shift Concerns/DTC's Set
- A/T - E4OD New Design Transmission Range Sensor
- On A/C Control Schematic - Manual Revision
- Diesel Engine - Idle Surge/Hard/No Start
- A/C - FX 15 Compressor Clutch Shaft and Hub Assembly
- Diesel Engine RPM Sensor - Manual Correction
- Recall 91V146000: Fuel Tank Selector Malfunction
- Speed Control - Abnormal Operation When Hot
- Driveability TSB's - Summary
- Engine - New Gasket Sealer
- Engine - Normal Oil Consumption
- Wire Harness - Terminal Repair Kit
- Wire Harness Terminal and Connector - Service Kit
- A/T - E4OD Proper Stoplamp Circuit Splicing
- Diesel Engine - Redesigned Fuel Return System
- Engine - Hard Starting/Poor Performance
- Engine - Stalls When Coming to A Stop
- Speed Control - Diagnostic Tips
- Paint - Cosmetic Damage From Airborn Materials
- Lower Body Stone Protection - Repair Procedure
- Paint - Preparation Procedure And MSDS Information
- Exterior Paint - Comprehensive Repair Procedures
- Overview
- Section A Has Been Superseded By TSB # 9264, Dated 3/92.
- (B) Paint Exterior Color Peeling From Ultra Violet Light
- (C) Lower Body Stone Protection Repair Tips
- (D) Procedure For PVC Body Side Moldings
- (E) Lower Body-Side Stone Chip Protection Program
- (F) Surface Defect Removal Without Repainting
- (G) Color Compatible Spray Primer Chart
- (H) Paint Repair For Tinted Clear Coat
- (I) Paintable Plastics
- (J) 1992 Paint Color Codes
- Paint - Iron Particle Removal
- A/C - Pressure Cycling Switch Diagnostic Procedure
- Electrical Diode - Identification and Replacement
- A/T - E40D Revised Rear Case Bushing
- Running Boards - Noise/Vibration Installation Tips
- A/T - AOD Buzzing At Idle/Grunting During Tip-In
- A/T - Main Controls/Separator Plate/Gaskets Usage
- A/T - AOD Separator Plate Gasket Changes
- Exhaust System - Excessive Heat On Cargo Floor
- Drivetrain - Lubricant Usage
- A/T - E4OD Redesigned Intermediate Band Apply Servo
- A/T - AOD 3/4 Shift Accumulator No Longer Required
- A/T - E4OD Service Case Replacement Service Tips
- A/C - R12 Refrigerant Service Tips
- A/C - R12 Refrigerant Substitutes Service Tip
- R-12 Refrigerant - Substitutes
- Air Conditioning - Use of Correct Fluorescent Tracer Dye
- A/C - Identification of Non Approved Refrigerants
- A/T - E4OD Upgraded Overdrive Planet Assembly
- M/T - M50D Hard Shift Condition
- M/T - Crunching Shifting From 2nd to 3rd Gear
- A/C Coupling - Cleaning Procedures
- Air Conditioning - O Ring Removal Service Tip
- A/C - New Refrigerant O-Rings
- A/T - E40D Clunk Shifting to Drive or Reverse
- Recall - E40D Transmission Output Shaft Snap Ring
- Engine RPM Sensor - Revised Test Procedures
- Engine RPM Sensor - Diagnostic Procedure Revision
- A/T - Harsh/Delayed 1st - 2nd and 2nd - 3rd Gear Shifts
- Defroster - Inadequate Output On Passenger Side
- Vehicle Storage - Maintenance Tips
- A/C - Spring Lock Connectors
- Diesel Engine - Fuel Requirements
- Front Alignment - Specifications
- A/C Compressor - Service Tips
- Seat Leather - Cleaning Procedure Tips