Repair and Diagnosis: Technical Service Bulletins
- How to Find Technical Service Bulletins by Category/Symptom
- Recalls
- Customer Interest
- Power Steering System - Noisy
- Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
- Engine - Hard Starting/Lack of Power
- Radio/Two-Way Communications - Whine/Buzz
- Fuel Pump - Whine Heard Through Radio Speakers
- Engine - Stalls/Quits Running
- Audio System - Whining/Buzzing Noise From Speakers
- Brakes - Soft Pedal Feel/Pull/Irregular Wear
- Heater Core - Failure/Leaks At Inlet Tube
- Steering Gear - Leak At the Input Shaft
- 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
- Wheel - Mounting Surface Distorted Lug/Pilot Holes
- A/T - Torque Converter Access Plug Dislodges
- Engine - Hesitation/Surge On Cruise/Light Acceleration
- Engine - Stalls On Transmission Gear Engagement
- A/T - E4OD Harsh/Double Bump On Reverse Engagement
- Full Float Rear Hub/Shaft - Lubricant Leaks
- Accessory Drive Belt - Comes Off Pulleys
- 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
- Generators - Low Power Output
- Instrument Cluster Warning Lights - Dimly Lit
- Engine - Stalls On Initial Start-Up
- Engine - Low End Knock Under Load
- EVAP System - MIL ON/Codes 171/173/179 Set
- Safety Belts - Front/Rear Twisted at `D' Ring
- Speedometer - Indicates High Speed When Cold
- Ignition Switch - Key Hard To Rotate When Cold
- Body/Frame - Water Leak Identification and Correction
- Rear View Mirror - Detaches From Windshield
- Engine - Knocking Noise on Initial Start Up
- A/T - E4OD Delayed Initial Forward Engagement
- A/T - E4OD Shift Concerns/DTC's Set
- Engine - Hesitation/Rough Idle/Stall
- Exterior Clearcoat - Cracking/Eroding/Peeling Off
- A/T - E4OD No 2nd - 3rd Gear Upshift
- A/T - E40D Clunk Shifting to Drive or Reverse
- A/T - E4OD Vehicle Does Not Move
- Engine - Rough Idle/Hesitation/Backfire/Stalling
- Chemicals,Additives
- Labor/Parts Updates
- Seals, Gaskets
- Superceded Bulletins
- 9174 - 04/05/91
- 91118 - 05/30/91
- 91109 - 05/15/91
- 90715 - 03/28/90
- 902612 - 12/19/90
- 90148 - 07/05/90
- 90137 - 06/20/90
- 90119 - 05/23/90
- 89165 - 08/09/89
- 88246 - 11/23/88
- 88245 - 11/23/88
- 87812 - 04/24/87
- 87716 - 04/08/87
- 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
- Power Steering Pump - Noise
- Power Steering Pump - Noisy
- Power Steering Pump - Noises
- 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
- Brakes - Special Lubricant Requirements
- 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
- No 2nd - 3rd gear Upshift
- A/T- E4OD/4R100 Parts Usage Chart
- A/T - E4OD Clunk During Gear Engagement
- A/T - E4OD Internal Part Usage Table
- A/T - E4OD Accumulator Body Usage Chart
- Fuel Economy - Customer Expectations Vs. Vehicle Usage
- Fuel Economy - Expectations Versus Usage
- Engine - Lower End Knock Under Load
- Speaker - Whining/Buzzing Noise
- Speakers - Whining/Buzzing Noise
- Fuel Pump - Buzz/Whine Through Radio Speakers
- Fuel Pump - Whine/Buzz Noise Heard In Speakers
- Radio - Whine/Buzz
- Radio - Buzzing/Whining Noise
- Engine - Stalling On Initial Start-Up
- Stumble/Rough Idle Install Deposit Resistant Injectors
- Fuel Injectors - Deposit Resistant Design Service
- A/T - E4OD MIL ON/DTC's 62/628/1728 Set
- Engine - Hesitation/Surge/Possible MIL ON
- Exhaust System - Buzz or Rattle Noise
- Exhaust System - Buzzing/Rattling Noises
- Exhaust System - Rattling/Buzzing Noise
- Exhaust System - Buzz/Rattle Noise
- Heater Core - Repeated Failure
- Cooling System - Diagnosis Procedure
- Engine - Start Up Knocking Noise
- 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
- Vehicle - Towing Guidelines
- Engine - Stumble or Rough Idle Condition
- Fuel Filter - Revised Scheduled Maintenance
- All Technical Service Bulletins
- Vehicle - Towing Behind RVs Guidelines
- 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
- Power Steering System - Noisy
- Engine Gasket Surface - Cleaning Procedures
- Engine - Repair Tips to Avoid Potential Damage
- Electrical - New Terminal Grease Released For Service
- Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
- Engine - Hard Starting/Lack of Power
- Radio/Two-Way Communications - Whine/Buzz
- Fuel Pump - Whine Heard Through Radio Speakers
- Engine - Stalls/Quits Running
- Audio System - Whining/Buzzing Noise From Speakers
- Brakes - Soft Pedal Feel/Pull/Irregular Wear
- Brakes - Intermittent Brake Squeal
- Engine - Lack of Power/No Start Diagnosis
- A/C Compressor - Oil Recovery/Measuring Procedures
- A/C Compressor - Oil Recovery and Measuring Procedure
- Air Conditioning - Approved Flushing Procedures
- Heater Core - Failure/Leaks At Inlet Tube
- Steering Gear - Leak At the Input Shaft
- Cooling System - New System Diagnostics
- 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
- Recall 93V073000: Rear Shock Crossmember Separation
- Wheel - Mounting Surface Distorted Lug/Pilot Holes
- Power Steering - Cooler Kit Availability
- Lug Nuts - Proper Installation/Torqueing Procedure
- Frame - Rivet Replacement with Bolts Service Tip
- 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
- Torque Converter - Cleaning and Replacement Guidelines
- A/T - In Line Service Check Valve Usage
- A/T - E40D In Line Service Check Valve Usage
- A/T Torque Converter - Leak Test Procedure
- A/T - Torque Converter Access Plug Dislodges
- Universal Joint - Greasable Design Availability
- Fuel Injector - New Cleaning Method
- Engine - Rough Idle or Stumble
- Fuel Injector Cleaner - Parts and Service Tips
- Deposit Resistant Fuel Injectors - Identification
- Engine - Hesitation/Surge On Cruise/Light Acceleration
- Engine - Stalls On Transmission Gear Engagement
- A/T - E4OD Harsh/Double Bump On Reverse Engagement
- Heated Exhaust Gas Oxygen Sensor - Application Chart
- EGO Sensors - Silicone Contamination
- EGR Valve Sensor - Obsolete Service Part Return
- Full Float Rear Hub/Shaft - Lubricant Leaks
- Accessory Drive Belt - Comes Off Pulleys
- Antilock Brakes - Service Tips
- 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
- Alternator - Discharge
- Generators - Low Power Output
- Instrument Cluster Warning Lights - Dimly Lit
- Engine - Stalls On Initial Start-Up
- Nylon Fuel Lines - Servicing Procedure
- A/T - E4OD Turbocharger/Supercharger Incompatible
- Engine - Low End Knock Under Load
- Accelerator Cable - Service Procedures/Tips
- EVAP System - MIL ON/Codes 171/173/179 Set
- Audio Systems - Authorized Service Centers
- Safety Belts - Front/Rear Twisted at `D' Ring
- Recall 91V172000: Seat Belt Anchor Replacement
- Ignition System - Diagnostic Procedures Revision
- Overview
- Ignition System Applications
- Initial Timing Set Procedure
- TFI-IV Ignition System
- Description and Schematic
- Preliminary Checkout, Equipment and Notes
- System Description
- Sensor Description
- Acronyms, Module, and Pin-Out
- Waveforms
- Block Diagram
- Wiring Schematic With Diagnostic Harness Installed
- Diagnostic Cable
- Testing
- Pinpoint Test Symptom Index
- Pinpoint Test A1 Thru A13
- Pinpoint Test A14 Thru A19
- Pinpoint Test A20 Thru A25
- Pinpoint Test AA1 Thru AA9
- Pinpoint Test AA10 Thru AA14
- Pinpoint Test AA15 Thru AA19
- Pinpoint Test AA20 Thru AA25
- Pinpoint Test AA26 Thru AA31
- Pinpoint Test B1 Thru B8
- Pinpoint Test C1 Thru C8
- Checkout and Notes For Intermittent Diagnosis
- Intermittent Diagnosis D1 Thru D10
- Secondary Ignition System Diagnosis
- Duraspark II Non-EEC Spark Timing Advance Test
- Symptom Index For Part I and II
- Part 1 Secondary System
- Part 2 Ignition System Test
- Visual Inspection, Equipment and Notes
- Test 1 Start Circuit
- Test 2 Run Circuit
- Test 3 Module Voltage
- Test 4 Ballast Resistor
- Test 5 Supply Voltage Circuits
- Test 6 Ign. Coil Supply Voltage
- Test 7 Distributor Stator and Wiring Harness
- Test 8 Ign. Module to Distributor Stator
- Test 9 Ign. Coil Secondary Resistance
- Test 10 Module to Coil Wire
- Test 11 Distributor Stator Assembly
- Test 12 Ign. Coil Primary Resistance
- Test 13 Primary Circuit Continuity
- Test 14 Ground Circuit Continuity
- Test 15 Distributor GRD. Circuit Continuity
- Intermittent Diagnosis
- IDM and Spark Timing Diagnosis - Manual Revision
- Starter Motor Brushes - Replacement Revision
- Horn Relay - Location Revision
- Speedometer - Indicates High Speed When Cold
- Heater Hose Illustration Headings - Revision
- Rear Anti-Lock Brakes - Adverse Characteristics
- Ignition Switch - Key Hard To Rotate When Cold
- Body/Frame - Water Leak Identification and Correction
- Key On Engine Off Self Test Code 79/539 - Revision
- EEC IV Quick Test - Manual Revision
- MIL ON/No Codes Set Explanation
- EEC IV - Self Test Codes and MIL Service Tips
- Overview
- Overview of Three Digit EEC-IV Self-Test Codes
- 1) Technician Not Familiar With Self-Test Code Output
- 2) Inadvertent Erasure of Continuous Memory Self-Test Codes
- 3) Concern Setting Continious Memory Code Isn't Present
- 4) Grounded STO/MIL Circuit
- 5) Engine Running In Hlos
- 6) Misinterpretation of MIL Bulb Check
- 7) MIL Flashes During Self-Test
- 8) Processor KAM Is Erased or Fails
- 9) Damaged Star Tester
- 10) KOEO Processor Ram Test Failed
- 11) Intermittent VSS Fault Detected In Wiggle Mode
- 12) IDM Pulswidth Not Recognized By Processor (EDIS Vehicles)
- 13) Intermittent Ignition System Fault
- 14) Intermittent Open STI Circuit
- 15) Power Lost to EEC Processor
- 16) Other Warning Lamps Mistaken For MIL
- 17) Development Testing /Wrong Processor Released to Production
- EEC IV Pinpoint Test H - Manual Correction
- Vehicle - Welding Precautions
- A/T - E4OD TCIL Flashing/DTC's 62/628/1728 Stored
- Door Latches - Adjustment/Modification Prohibition
- Windshield/Interior Glass - Fog/Film
- Glass - Iridescence or Mottling In Tempered Glass
- Rear View Mirror - Detaches From Windshield
- Rear View Mirror - Reattachment
- Engine - Oil Fill Capacities
- Motor Oil - Viscosity Grade Recommendation
- Cooling System - Proper Fluid Concentrations
- Recycled Engine Coolant - Service Tips
- Engine Coolant - Propylene Glycol Recommendations
- Engine - Knocking Noise on Initial Start Up
- Brake Hoses - Wet Appearance
- A/T - E4OD Delayed Initial Forward Engagement
- 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
- 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 - E40D Adhesive Repair Kit Availability
- A/T - E40D/ATX Transmission Exchange Program
- A/T - E4OD Upgrade Ball Bearing Center Support Kit
- A/T - E4OD Diagnostics Revision/Correction
- 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 - Harsh Reverse Engagements
- A/T - Engine Vacuum Testing
- A/T - E40D Quick Tests
- A/T - Delayed Engagement In Reverse and Drive
- A/T - How To Use A Pressure Gauge
- A/T - E40D Burned Overdrive Section
- A/T - Buzzing Noise/Missing Cup Plugs
- 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 - Failsafe Modes
- A/T - E40D No Converter Engage, 2nd and 4th Gear Starts
- 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 Vibration When TCC is Applied
- 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 - Intermediate Accumulator Regulator Filter/Spring
- 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
- A/T - Mercon V ATF Usage
- A/T - E4OD Shift Concerns/DTC's Set
- A/T - E4OD New Design Transmission Range Sensor
- Recall 91V146000: Fuel Tank Selector Malfunction
- Recall - Fuel Tank Selector Valve Replacement
- Fuel Tank Switching Valve - Service Tips
- Engine - New Gasket Sealer
- Wire Harness - Terminal Repair Kit
- A/T - E4OD Proper Stoplamp Circuit Splicing
- Fuel System - Fuel Stabilizer For Extended Storage
- Fuel Economy - Customer Expectation vs. Vehicle Usage
- Speed Control - Diagnostic Tips
- Engine - Hesitation/Rough Idle/Stall
- Remote Keyless Entry System - Service Highlights
- Plastic Credit Card Keys - Cutting Procedure
- Paint - Preparation Procedure And MSDS Information
- Paint - Color Code Chart Revision
- Exterior Clearcoat - Cracking/Eroding/Peeling Off
- 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
- Electrical Diode - Identification and Replacement
- A/T - E40D Revised Rear Case Bushing
- Running Boards - Noise/Vibration Installation Tips
- A/T - Main Controls/Separator Plate/Gaskets Usage
- A/T - E4OD No 2nd - 3rd Gear Upshift
- Campaign - Running Light Module, Extended Coverage
- A/T - E4OD Redesigned Intermediate Band Apply Servo
- 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
- 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
- Trailer Brake Controller - Stoplamp Circuit Installation
- A/T - E4OD Vehicle Does Not Move
- Brakes - New Silicone Compound/Grease
- Engine - Rough Idle/Hesitation/Backfire/Stalling
- Fuel - California Reformulated Gasoline
- A/C - Adding Refrigerant Oil Service Tip
- A/C Compressor - Service Tips
- Seat Leather - Cleaning Procedure Tips