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1997 Ford Technical Service Bulletins

1. ENGINE ERATURE BELOW 88 C 1807 15 THERE POWER 21 FP PIN 1 BACK KOER BACK PROBE PIN AT PROBE PIN 28 AT C171 THERE C110 18 THERE POWER POWER CHART G ELECTRONIC CONTROL MODULE CHECK IS THE VEHICLE ECIUPPED WITH FAN OVERRIDE SWITCH BETWEEN H1 AND GROUND AT C135 KOER DOES FAN STOP IN 3 MINUTES OR Figure 8 Article 97 22 18 PARKING BRAKE APPLIED KOER TOGGLE SWITCH DOES FAN STOP IN 3 MINUTES Oft LESS BETWEEN PINS 29 AND 38 AT C110 DOES FAN STOP IN 3 MINUTES OR LESS JUMPER BETWEEN C171 PIN T AND C170 PIN 10 KOER DOES FAN STOP IN 3 MINUTES OR CHART HGH PRESSURE RELAY WIRING REMOVE HIGH PRESSURE 15 THERE RELAY 8 15 JUMPER PINS 3 AND 4 AT FIP KOER DO a HF IS THERE GROUND ON R 15 F P PIN 2 OR 1 18 VEHICLE EQUIPPED WITH DISCONNECT IS VEHICLE a FAN OVERRIDE EQUIPPED WITH 3 CONTINU SWITCH IS THERE GROUND FAN OVERRIDE PRESENT ACROSS AC HIGH ON FP PIN 1 SWITCH PRESSURE SWITCH OR 21 FAN SIDE REPAIR SHORT TO GROUND ON CKT 90 Figure 9 Article 97 22 18 CHART I AAG HIGH PRESSURE RELAY WIRING DISCONNECT C108 IS CONTINUITY PRESENT BETWEEN C106 PIN 2 AND 1 F P PIN 4 IS CONTINUITY PRESENT BETWEEN C106 15 AND 15 F F PIN 3 OH 4 I8 CONTINUITY PRESENT BETWEEN C106 PIN 2 AND C110 PIN 38 I CONTINUITY I
2. 480 STM VO Dump LB513 FGHZ EFZ5O FA MUFELER CATALYST SHM Single Horizonte CCM with Hornets v Single Horizontal with Yerticad Outlet Pipa included on service Single Verka d not included or perrea ATH Single CC ld with Cutis rage required on warvirm CCM GTH with Vertical Curt ur Singla Horizontal CCM with Verica Outlet Pipa Routed Under Eraras OF Single Horizontal CCM with Vertical Outlet Pipa Routed Over Frame STM Bev Single Transverse for Application Dump Single Tangverse CCM dor Dump Application STH YO Dump Single Trensveres with Vertical Outlet for Dump Application NOTE Tha following hama ara required for FO LACE with 300 CPS C Ma DESCRIPTION PART NUMBER LCP wfihour aan SVM 6 Dameg CCM Outlet Pips for 5 DBHZ 5258A 5 Diameter CCM Outlet Pipe for E CCM ER EDES A 1 5 ameer Ouest Camo tor 6 CCM ETHZ 5A231 H 11 INCH SVO FACE L A 8501 4513 F4HZ ED224 SHM FAHZ ED223 E SHM 8501 8813 FAHZ 50223 E Suc L SERIES 215 STRAIGHT FRAME L SERIES EJHZ 54215 8 VARIABLE FRAME 10 INCH DIA F LO PROFILE 4MZ 5D423 D DESCRIPTION C 542 5420
3. 5F260 A OASIS CODES 403000 602300 614000 614500 614600 97 7 Publication Date 31 1997 Article No Sun Visor Optional Roof Mounted Sun Visor Vibrates At Highway Speeds 97 7 15 MEDIUM HEAVY TRUCK 1996 97 AEROMAX LOUISVILLE ISSUE The optional roof mounted sun visor may vibrate excessively at highway speeds This may be caused by the attaching bolts not properly securing the sun visor to the roof ACTION Replace the current fasteners and add two 2 additional fasteners The new fasteners and the additional two 2 fasteners should improve the mounting of the sun visor and reduce the possibility of vibration Refer to the following Service Procedure for details SERVICE PROCEDURE 1 Remove the six 6 existing sun visor to roof attaching screws and discard 2 Remove the sun visor and place it on a workbench 3 determine the location of the two 2 new sun visor attaching bolts first measure the length of the sun visor to determine its centerpoint and mark Refer to Figure 1 NEW NEW ATTACHING HOLE 127mm 57 ATTACHING HOLE 63 5mm EXISTING 2 57 EXISTING ATTACHING HOLE ATTACHING HOLE lt gt 38mm 1 57 lt gt SUN VISOR CENTERPOINT SUN VISOR Figure 1 Article 97 7 15 4 Outboard from the centerpoint measure 63 5mm 2 5 to each side and mark Refer to Figure 1 5 Measure from the rear edge of the visor forward 38mm 1 5 and mark Refer to Fi
4. Kada Order d Allume Debit combust 1 uias indiques Data ol Min 3971620 kila Speed rpm Advertised HP Date of Gestion Pulse Indlquee ch TB 4168 Figure 1 Article 97 6 30 CCM DESIGN AND SERVICEABILITY The COM looks very similar to a conventional muffler however the CCM contains an oxidation catalyst Refer to Figure 2 CATALYTIC CONVERTER MUFFLER TYPICAL CATALYST MUFFLER 4 DIRECTION Figure 2 Article 97 6 30 The CCM is repairable It must be replaced with the correct CCM e Low sulfur diesel fuel must be used High sulfur diesel fuel can reduce the efficiency of the CCM WARNING EXPOSURE TO SULFATES HAS BEEN SHOWN TO RESULT IN RESPIRATORY DISCOMFORT THE USE OF HIGH SULFUR DIESEL FUEL ABOVE 0 5 SULFUR BY WEIGHT MAXIMUM WILL RESULT IN SULFATE FORMATION IN THE EXHAUST GAS UNDER HIGH LOAD CONTINUOUS USE e Blending waste lubricating oil in the fuel is not permitted The blended oil will accumulate on the catalyst and plug the CCM e Internal engine turbocharger and fuel injector failures may allow debris excessive engine oil and or fuel to accumulate on the catalyst and plug the CCM e The original equipment OE horizontal mounting straps are not reusable The production straps can be removed and new service straps installed Depending on the part number a service CCM may come with mounting straps Refer to Figure 3 for applica
5. When the engine is cold start the engine allow it to run at its normal idle speed and monitor the temperature of the engine oil pan A hand held infrared temperature meter or a Digital Volt Ohm Meter DVOM with a temperature probe may be used The engine oil oil pan provides an accessible reading point for engine temperature and also correlates to the engine coolant temperature NOTE ON CERTAIN VEHICLES A NOISE SHIELD HAS BEEN MOUNTED ONTO THE EXTERIOR OF THE OIL PAN IT 1 IMPORTANT THEREFORE SURE THE TEMPERATURE READINGS ARE TAKEN DIRECTLY FROM THE OIL PAN OTHERWISE THE TEMPERATURE READINGS WILL NOT BE ACCURATE NOTE INEXTREME COLD AMBIENTS IT MAY BE NECESSARY TO OPERATE THE ENGINE AT SPEEDS HIGHER THAN IDLE OR WITH THE ENGINE UNDER LOAD SO THAT IT IS ABLE TO OBTAIN THE TEMPERATURES LISTED IN STEP 2 a Once the engine oil oil pan reaches approximately 57 66 C 135 150 F white smoke should no longer be emitted from the exhaust The 57 66 135 150 F engine oil oil pan temperature correlates to the engine coolant temperature gauge reading at about the beginning of the normal range If the engine exhaust system emits white smoke during the initial warm up of the engine but the white smoke is gone by the time the engine oil oil pan temperature reaches 57 66 135 150 F and no other engine driveability concerns exist the engine is operating properly and no further action should be taken If the engine
6. REFERENCE BRAKE JOUNCE HOSE BULKHEAD FITTING 5215 Figure 4 Article 97 19 21 5 Replace the two 2 existing pitman arms with revised Pitman Arms F8HZ 3590 CA Right Side and F8HZ 3590 DA Left Side Figure 3 6 Check the front end caster and toe in and if necessary adjust to specifications listed in the appropriate Louisville AeroMax Service Manual Section 04 00 OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 303000 304000 97 19 Publication Date SEPTEMBER 15 1997 Tachometer Inoperative And Or Erratic Vehicles Equipped With CAT 3306 Cummins Article No 1060 Or Cummins 1460 Mechanical Engine 97 19 22 MEDIUM HEAVY TRUCK 1996 98 AEROMAX LOUISVILLE ISSUE The tachometer may become inoperative and or erratic on some vehicles equipped with a mechanical engine This may be due to a defective and or improperly adjusted tachometer sensor ACTION Install a new tachometer sensor that has a plastic spacer used to set initial gap The correct gap should reduce the possibility of an inoperative and or erratic tachometer Refer to the following Service Procedure for details SERVICE PROCEDURE 1 Check the tachometer sensor output voltage signal at the wire harness connector on the tachometer gauge Output voltage must be measured with the connector attached to the gauge and the engine at an idle a
7. 97 1 Publication Date JANUARY 2 1997 Service Manual Powertrain Control Emissions Diagnosis PC ED On Board Diagnosis Il Cover Page Replacement To Include 1997 Vehicles With Article No FD1060 Or FD1460 Engine 97 1 15 Service Manual Powertrain Control Emissions Diagnosis PC ED On Board Diagnosis 1 Cover Page Replacement To Include 1997 Windstar LIGHT TRUCK 1997 WINDSTAR MEDIUM HEAVY TRUCK 1997 CARGO SERIES F amp B SERIES L SERIES This TSB article is being republished in its entirety to include reference to FD1060 and FD1460 engines ISSUE The 1996 Powertrain Control Emissions Diagnosis PC ED On Board Diagnostics II OBD II Service Manual is required to service driveability concerns for the 1997 Windstar The 1996 PC ED OBD Service Manual is required to service 1997 vehicles with an FD1060 or FD1460 diesel engine ACTION Refer to the 1996 PC ED OBD II Service Manual for servicing driveability concerns on the 1997 Windstar and refer to the 1996 PC ED OBD Service Manual for servicing driveability concerns on the 1997 FD1060 and FD1460 diesel F amp B Cargo L Series vehicles Replace the existing 1997 PC ED OBD II Service Manual cover page with the new cover page that includes a reference note to the 1997 Windstar and FD1060 and FD1460 diesel engines OTHER APPLICABLE ARTICLES NONE SUPERSEDES 96 22 14 WARRANTY STATUS INFORMATION ONLY OASIS CODES 190000 290
8. For individual case gauges measure voltage between Pins 4 and 7 b electronic cluster gauges measure voltage between Pins 1 and 10 2 Ifthe voltage is less than 1 5 volts replace the tachometer sensor NOTE THE ELECTRICAL CONNECTOR ON THE NEW TACHOMETER SENSOR WILL NOT CONNECT TO THE EXISTING TACHOMETER SENSOR CONNECTOR OF THE 14289 WIRE HARNESS IN ORDER TO CONNECT THE NEW SENSOR TO THE WIRE HARNESS IT WILL BE NECESSARY TO REMOVE BOTH THE SENSOR AND WIRE HARNESS CONNECTORS AND SPLICE THE SENSORS DIRECTLY TO THE HARNESS WIRES OR USE A QUALITY WATERPROOF TWO PIN AFTERMARKET CONNECTOR TO CONNECT THE SENSOR TO THE HARNESS REFER TO THE SPLICING PROCEDURES FOUND IN TSB 96 16 3 TO ENSURE A QUALITY ELECTRICAL CONNECTION DUE TO THE TYPE OF SIGNAL GENERATED BY THE TACHOMETER SENSOR EITHER ONE OF THE SENSOR WIRES MAY BE CONNECTED TO EITHER ONE OF THE HARNESS WIRES FOR THE SENSOR AND GAUGE TO FUNCTION PROPERLY 3 Adjust the new sensor by rotating the sensor clockwise until it contacts the flywheel Tighten the jam nut to 27 34 20 25 lb ft Operating the engine will remove the plastic spacer 4 Ifthe sensor is removed and reinstalled after the initial adjustment procedure it can be adjusted by rotating the sensor clockwise until it contacts the flywheel and then backing off 1 4 to 1 2 turn The correct sensor should be 1 25mm 0 050 OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Cove
9. Vehicles Built Through 1 14 97 e Engine Premium Electronic Diesel Intermittent Or No Signal From Vehicle Speed Sensor VSS Vehicles Built Through 1 14 97 MEDIUM HEAVY TRUCK 1997 LOUISVILLE ISSUE A loss of power and inoperative or erratic speedometer and cruise control may occur on some vehicles The Malfunction Indicator Lamp MIL may illuminate with Electronic Control Module ECM fault codes e 31 and 36 for CAT engines e 241 and 242 for Cummins engines e 54 and 58 for DDC engines This may be caused by a complete or intermittent loss of the Vehicle Speed Sensor VSS signal to the ECM ACTION Verify wire harness and connector integrity by referring to the following Service Procedure Steps 1 3 Refer to Step 4 if engine loss of power occurs after the instrument cluster has been heat soaked through normal operation In addition refer to the 1997 Louisville AeroMax Service Manual Sections 03 and 13 for normal diagnostic and repair of the VSS cruise control and instrumentation warning systems SERVICE PROCEDURE 1 VSS Connector Terminal Crimp a Unplug the VSS connector at the transmission NOTE THE WIRE ASSEMBLY CONNECTOR USED AT THE VSS IS A PULL TO SEAT TYPE CONNECTOR TO INSPECT THE WIRE TERMINAL CRIMPS CAREFULLY PUSH THE TERMINALS AND WIRES TOWARD THE FRONT OF THE CONNECTOR HARD SHELL b Each terminal will have separate insulation and conductor crimps If both insulation and conductor
10. have been crimped at the conductor crimp location this will result in a loss of conductor integrity at the crimp and an intermittent or continuous loss of the vehicle speed input signal to the speedometer loss of conductor integrity is found go to the following Step 1 c Replace the connector assembly with Connector Kit F6HZ 14A464 DEA Refer to TSB 97 10 13 for additional kit information 2 Electronic Control Module ECM Connector Terminal Crimp 12A581 Wire Assembly DDC Series 60 Engines a Unplug the 12A581 wire assembly to the ECM connector NOTE THE WIRE ASSEMBLY CONNECTOR USED AT THE ECM IS A PULL TO SEAT CONNECTOR TO INSPECT THE VEHICLE SPEED INPUT CIRCUIT CK 614 GREEN LOCATED AT PIN E2 CAREFULLY PUSH THE TERMINAL AND WIRE TOWARD THE FRONT OF THE CONNECTOR HARD SHELL b The terminal will have separate insulation and conductor crimps If both insulation and conductor have been crimped at the conductor crimp this will result in a loss of conductor integrity at the crimp and an intermittent or continuous loss of the vehicle speed input signal to the ECM If loss of conducior integrity is found go to Step 2c c Replace the damaged terminal with a terminal and wire pigtail assembly from the VSS Connector Kit FOHZ 14A464 DEA Refer to TSB 97 10 13 for additional kit information 3 Speedometer Head 16 Way Connector Terminals 14401 Wire Assembly a If Steps 1a 2c indicate no problem and
11. 3 3 WATER ORAIN TUBE ASSY SVM L A 8501 8513 0421 52203 WATER DRAIN TUBE ASSY SVM ALL MODELS 3755 5111 ELBOW ALL MODELS PU BAC Engan LABEL An Z BDADQE B French NO FUELCIL BLENDING All Exhaust _ ENGINE 1 EXHAUST was PART NUMBERS 2 DESCHPTON 060201450 ALL ALL 4 2 231 TORCA CLAMP FOR USE W TH SLOTTED INLET PIPE NOTE The TORCA clamp bolt must be between the on the and TRA plis aw TORCA damp is included mach new services CCM H a inlet pipa clamp should be used NOTE CCH Inlet piped are 409 atainiess or with TORCA nlote at the COM end TB 3744 C Figure 3 Article 97 6 30 If the catalyst inlet pipe is modified e g for installation of an exhaust brake any new inlet pipes must be made of stainless steel grade 409 or higher to prevent interior pipe rust from plugging the catalyst Vertical CCM s have a water drain system to prevent water from contacting the catalyst The water drain system consisting of an internal water trap a drain port a 90 degree elbow and a water drain tube drains water away from the catalyst and directs it to the ground The drain tube should be checked periodically to make sure it is not restricted Horizontal CCM s with vertical outlet pipes have two 2 1 4 diameter water drain holes on the bottom of the Th
12. Equipped With Detroit Diesel Engine Article No With Vertical Exhaust Built Through 5 3 97 97 16 13 MEDIUM HEAVY TRUCK 1996 98 AEROMAX LOUISVILLE ISSUE The exhaust pipe may crack on some vehicles at the muffler inlet The original exhaust pipe is not robust enough and results in cracking around the pipe flange where it mates with the turbocharger outlet ACTION Replace the muffler inlet pipe with a revised pipe to reduce the potential for cracking Refer to Section 09 00 of the appropriate Louisville AeroMax Service Manual for removal and installation procedures PART NUMBER PART NAME 5218 Muffler Inlet Pipe OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME 16155 Replace Inlet Pipe 0 7 Hr DEALER CODING BASIC PART NO CONDITION CODE 5246 OASIS CODES 403000 97 18 Publication Date SEPTEMBER 2 1997 Article No Brakes Air Brake Governor Operational Specifications Service 97 18 14 MEDIUM HEAVY TRUCK 1998 AEROMAX amp SERIES LOUISVILLE ISSUE The specification for the air brake governor cut in and cut out on vehicles equipped with air brakes has been changed starting with vehicles built after 3 1 97 This is due to a change in Federal Regulations concerning air brake systems ACTION Refer to the following text for the new specifications Additional
13. ONLY CROSS SECTION VIEW OF HOOD NEW RIVET CENTER REAR REINFORCEMENT LOCATIONS AND HOOD OUTER SHELL VEHICLE 50 6mm 153 8mm 241 8mm 5208 Figure 4 Article 97 23 16 If evidence of a separation between hood center reinforcement and the hood side reinforcements is present proceed to Step 2 If no evidence is present the following repair is not needed NOTE SIX 6 NEW RIVETS WILL BE USED TO SECURE THE HOOD CENTER REAR REINFORCEMENT TO THE HOOD SIDE REINFORCEMENTS THE INSTALLATION OF THE NEW RIVETS CAN BE DONE WITHOUT REMOVING THE HOOD FROM THE VEHICLE 2 Using the information provided in Figures 1 5 determine and mark the location for all six 6 new rivet holes on the hood center rear reinforcement Six 6 rivets will be used three 3 on the left and three 3 on the right side Figure 1 Article 97 23 16 CAUTION ONLY DRILL THROUGH THE HOOD CENTER REAR AND HOOD SIDE REINFORCEMENTS BE CAREFUL NOT TO DRILL INTO OR THROUGH THE OUTER SHELL OF THE HOOD 3 Make sure the hood center rear reinforcement is fully seated against the hood side reinforcements and drill six 6 new 6 75mm 17 64 holes through the reinforcements at the locations marked Figures 2 through 5 4 Make sure the hood center rear reinforcement is still fully seated against the hood side reinforcements then using a suitable rivet tool install one 1 W525174 S rivet into
14. PROCEDURE REFER TO THE APPROPRIATE MODEL YEAR SERVICE MANUAL SECTION 03A 05 NOTE ON EARLY BUILT FD1060 ENGINES THE TENSIONER AND IDLER SUPPORT PLATES WERE ATTACHED TO THE ENGINE WITH COUNTERSUNK BOLTS REFER TO FIGURE 2 THE NEW IDLER AND SUPPORT PLATE ASSEMBLY NOW USES HEX HEAD FLANGE BOLTS THEREFORE IF AN ENGINE IS EQUIPPED WITH THE COUNTERSUNK BOLTS THEN THOSE BOLTS MUST BE REPLACED WITH NEW HEX HEAD FLANGE BOLTS 3900631 CF Figure 2 Article 97 4 11 4 Remove the automatic belt tensioner from the support plate and then remove the support plate from the engine Discard the support plate Refer to Figure 1 DRIVE BELT TENSIONER ATTAGHING BOLT SUPPORT PLATE AUTOMATIC BELT TENSIONER Figure 1 Article 97 4 11 NOTE IF THE AUTOMATIC BELT TENSIONER IS EQUIPPED WITH A PLASTIC PULLEY THEN REFER TO TSB 96 8 23 FOR INFORMATION REGARDING AN IMPROVED AUTOMATIC TENSIONER 5 Install the new automatic Belt Tensioner Support Plate F3HZ 6B209 AAA onto the engine with the two 2 attaching bolts Torque the bolts to 20 32 N m 15 24 lb ft 6 Install the automatic belt tensioner onto the support plate with one 1 bolt and torque to 41 52 N m 30 38 Ib ft 7 If the vehicle is equipped with air conditioning proceed to Step 9 If the vehicle is not equipped with air conditioning proceed to Step 8 8 Remove the idler pulley and support plate assembly from the engine and discard Install the new Idler Pul
15. Repair Kits Chart in this TSB article to order the proper repair kit The connector repair kits provide service to in line and component connectors fuse panel and power distribution box terminals and bulkhead connectors IN LINE AND COMPONENT CONNECTORS Each kit contains a connector pigtail assemblies terminals and butt splice crimped to a 203mm 8 wire and applicable spacer and grommet The kit contains material to completely replace an entire connector independent of usage FUSE PANEL POWER DISTRIBUTION BOX AND BULKHEAD TERMINALS Each kit contains pigtail assemblies in various wire gauges to provide terminal replacement for one of the following components e Fuses Relays e Circuit Breakers Customer Access Studs Bulkhead Connectors cab and engine compartment BULKHEAD CONNECTOR Each cab and engine compartment bulkhead connector 1 offered individually CONNECTOR REPAIR KITS Service Part Number Instruction Sheet 1 5 Number Rear axle shitt control switch Rectangular headlamp Gauges transmission temperature engine ail temperature rear axle temperature water temperature voltmeter fuel Iqnitian switch Blower motor switch Courtesy lamp switch Engine temperature ether start switch and warning Indicator switches transmission nil engine oil water stoplamp low pressure switch speed axle selector motor Turn emergency signal switch UT CONNECTOR REPAIR KITS Cont d Service
16. TO 20 N m 15 LB FT FOLLOWING A STAR PATTERN THEN REPEAT THE STAR PATTERN AND TORQUE TO 34 N m 25 LB FT APPLICATION CHART F1HT 5600 LA F1HT BBDLD MA 1 8600 F1HT 6600 KA FAHT SEO0 BA 9600 PART NUMBER PART NAME Fr HZ 0600 EA Fr HZ 6600 FA Fr HZ 0600 GA Fr HZ 0600 HA Fr HzZ Bb D JA F HZ 6600 HA F z HZ 6600 EA Fz HZ 0600 F A F z HZ 0600 JA F z HZ 0600 GA OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING 1 OASIS CODES 402000 499000 97 5 Publication Date 3 1997 Article No Engine Diesel FD1060 And FD1460 White Smoke From Exhaust ervice Tip 97 5 17 MEDIUM HEAVY TRUCK 1992 97 SERIES F amp SERIES SERIES 1997 LOUISVILLE ISSUE White smoke from the exhaust system of a diesel engine during initial warm up in cold ambient temperatures is normal in most cases It is caused by the incomplete combustion of the air fuel mixture resulting from low engine operating temperatures and cold ambients However once the engine temperature warms the amount of white smoke present in the exhaust should diminish ACTION To help identify whether the white smoke is a normal condition caused by a cold engine and cold ambients refer to the following Diagnostic Procedure for details DIAGNOSTIC PROCEDURE 1
17. as was measured in Step 3 c Make sure the orientation of the rod is the same as the original d Tighten the stop nut against the new rod end 9 Install the clutch rod onto the vehicle a Place the clutch rod either inboard or outboard of the clutch release lever as was noted in Step 1 b Install the new Bolt 58638 8100 through the new Washer 391817 5421 the new rod end and then through the clutch release lever Install the new Nut 382802 36 onto the bolt Torque the nut to 42 57 N m 31 42 Ib ft Do not exceed this torque value C A Attach the upper end of the clutch rod onto the clutch pedal shaft and lever Install a new Nut 391494 52 and torque the nut to 42 57 N m 31 42 lb ft 10 Cycle the clutch pedal several times to be sure the linkage operates correctly NOTE THIS PROCEDURE SHOULD NOT AFFECT THE CLUTCH PEDAL ADJUSTMENT HOWEVER IF CLUTCH PEDAL ADJUSTMENT IS NEEDED REFER TO SECTION 08 02 OF THE APPROPRIATE YEAR LOUISVILLE AEROMAX SERVICE MANUAL FOR THE ADJUSTMENT PROCEDURE F HzZ 7B537 C C Clutch Rod Elastomeric End Bolt 3 5 16 2 0 Mut 3 8 16 Lack Washer 3 8 Mut 3 8 34 Jam Mut 3 8 24 P T OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME 34712154 Replace Clutch Rod End 0 7 Hr DEALER CODING BASIC PART NO CONDITION CODE 7521 33 OASIS CODES 497000 506000 597997 702000 97 13 Pu
18. concern It is very important that each Step or Test in the diagnostics be followed and or performed in order to be sure that the root cause of the concern is identified FAN CLUTCH OPERATION DIAGNOSTICS Figure 1 Article 97 22 18 FAN WILL NOT ENGAGE WITH HIGH REFRIGERANT PRESSURES APPLY PARKING BRAKE DOES THE FAN START CHART FAN WILL NOT ENGAGE HORTON FAN CLUTCH VOLT DROP 57 BETWEEN THE SOLENOID AND GROUND IS THE VOLTAGE GREATER THAN 0 2 REPAIR 57 GROUND Figure 2 Article 97 22 18 KOER IS CKT POWERED AT THE FAN CONTROL SOLENOID IS THERE POWER PIN 3 OR A 217 REPAIR OPEN 838 GHECK LOCATION CKT 936 AT R 21 REMOVE THE FAN CONTROL RELAY F 21 JUMPER PINS 3 AND 4 AT THE FUSE PANEL KOER DOES THE FAN ENGAGE REPAIR OPEN IN CKT 517 CHECK FUSE 12 AND LOCATION OF CKT 517 AT 21 CHART FAN WILL ENGAGE BENDIX AND KYSOR FAN CLUTCHES KOER IS 936 POWERED THE REMOVE THE FAN GONTROL RELAY Bei GEN 21 DOES THE FAN ENGAGE I THERE F P PIN3 OR 4 FOR 21 REPAIR MISWIRED FAN CONTROL RELAY Figure 3 Article 97 22 18 CHART FAN WILL ENGAGE ALL FAN CLUTCHES NOTE ECM ELECTRONIC CONTROL MODULE REMOVE FAN CONTROL RELAY 21 15 THERE POWER ON FIP PIN 1 OR 2 REMOV
19. dash Locate identify the leaking air valve Release any air pressure left in the system Remove the two 2 air lines from the valve by pushing in on the tube depressing the collet and then pulling the tube out of the fitting If a fitting has been exposed to particulary harsh conditions or has been in service for a long period of time it may be necessary to grip the collet with a pair of pliers and rotate the collet slightly to help free the components Additional information regarding Push To Connect fittings can be found on Page 06 08 3 of the appropriate year Louisville Aeromax Service Manual 7 Squeeze the valve tangs that retain the valve to the instrument panel and remove the valve from the panel 8 Install a new valve into the instrument panel in place of the original NOTE BEFORE CONNECTING THE TUBES INTO THE NEW VALVE CHECK THE END OF THE TUBE AND BE SURE IT IS CUT SQUARE AND THAT THE TUBE END IS NOT DISTORTED OR DAMAGED THE MAXIMUM ALLOWABLE ANGLE IS 15 DEGREES IF THE ANGLE OF THE CUT EXCEEDS THIS SPECIFICATION RE CUT THE TUBE USE A SHARP BLADED CUTTING TOOL THAT WILL NOT COLLAPSE THE TUBE OR LEAVE BURRS ON THE TUBE END THAT COULD DAMAGE THE O RING 9 Make sure the air tubes are installed in the same position on the new valve as they were on the original Insert each tube into the fitting until it is fully seated A small resistance will be felt as the tube passes the collet teeth and the O ring Pull back on the t
20. illumination fuel voltmeter brake application pressure air pressure ol FBHZ 14 amp 454 D 15 pressure rear axle temperature water temperature engine ail temperature transmission ail temperature Message center FRA 144464 DKA4 Oimmerdome switch multi function switch Signal Stat FEHZ 144454 DLA CONNECTOR REPAIR KITS Cont d Service Part Humber Instruction Sheet 1 5 Number Switches engine brake min max 21 000 brake min max clearance lamprblink engine shutdown override COCHO pressure governor system enable engine idle Cummins exhaust brake control heated mirror speed axle trailer hook up fan override engine brake on off CAT DDCI raad fag lamp 7 14 4 For 144464 DNA 14 4 4 hot post Blower motor resistor Allison HO 4000 Series transmission 1 in line connector 14501114209 wire assemblies 1 In line connector 124501714299 wire assemblies Customer access Allison electronic automatic transmission Engine customer access Cummins 11 14 and CAT 3175 3406 Circuit breaker terminals Fuse terminals Relay terminals Bulkhead connector terminals cab Bulkhead connector terminals engine compartment Customer access fuse panel eyelets Back up lamp switch manual transmission Low coolant level sensor mechanical DDC idle validation switch Gauges fuel voltmeter water temperature rear axle temperature engine all
21. information regarding air brake supply systems and the air brake governor can be found in Section 06 of the appropriate Service Manual For vehicles built after 3 1 97 the air brake governor specifications are e Cut in pressure 765 76 kPa 111 11 PSI e X Cut out pressure 896 34 kPa 130 5 PSI For vehicles built before 3 1 97 the air brake governor specifications are e X Cutin pressure When pressure drops below cut out pressure by 83 179 kPa 12 26 PSI X Cut out pressure 827 34 kPa 120 5 PSI OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS INFORMATION ONLY OASIS CODES 301000 302000 390000 Bulletin Contents TSB Article 97 18 15 has been superseded by Article 97 19 23 Bulletin Contents TSB Article 97 18 16 has been superseded by Article 97 19 24 97 18 Publication Date SEPTEMBER 2 1997 Article No Engine Electronically Controlled Engine Service Caution 07 18 17 MEDIUM HEAVY TRUCK 1995 98 L SERIES LOUISVILLE ISSUE A service caution is necessary when reprogramming electronic diesel engine management systems Powertrain Control Module Electronic Control Unit ACTION Some electronically controlled diesel engines can be modified to increase engine output by altering the original engine management system Such modification may result in damage to the drivetrain and chassis components designed to accommodate original engine output levels These modifications ma
22. module in series with the Signal Stat multi function switch will allow the 4 way flashers to function with the service brake applied Refer to the following Service Procedure for details NOTE THIS INFORMATION IS ONLY APPLICABLE TO THE SIGNAL STAT TRACTOR PACKAGE TURN SIGNAL SYSTEM SERVICE PROCEDURE This is an information only TSB article This is a Domestic Special Order DSO option that the customer may now need due to a change in the vocation of the truck Start with Step 1 for electronic engines For mechanical engines start with Step 2 1 If equipped with an electronic engine remove the Deutsch engine diagnostic plug bracket mounted below the instrument panel on the left side of the steering column Install a new Module Mounting Bracket F7HZ 14A206 BB and relocate the Deutsch engine diagnsotic plug to the new mounting bracket 2 On mechanical engines install a Module Mounting Bracket F7HZ 14A206 BB below the instrument panel on the left side of the steering column 3 Disconnect Connector C254 from the Signal Stat multi function switch and install a Brake Override Module F7HZ 13A318 BA in series Mount the Brake Override Module to the new mounting bracket Refer to the Louisville AeroMax Electrical and Vacuum Troubleshooting Manual EVTM Page 90 2 4 Plug the Ground Wire 2 14 000 into the module ground terminal and the eyelet into a suitable ground location A ground possibility would be the fuse panel t
23. open throttle WOT limit maximum engine speed The FD engines under these conditions will reach speeds from 10 to 17 percent above their rated rpm If the engine is unable to reach its high idle no load WOT limit maximum speed rated rpm plus 1096 it will be necessary to first diagnose and repair this concern before the back pressure test can be performed Failure to reach rated rpm plus 1096 could be caused by a misadjusted throttle linkage incorrect engine timing fuel system restrictions or base engine concerns A COM that is severely plugged could also prevent the engine from reaching its high idle no load WOT limit maximum speed rated rom plus 10 In this case record the engine rpm and the CCM back pressure at the maximum obtainable engine speed in the comment section of the Repair Order and then replace the CCM 7 With engine operating 10 percent above its rated rom e g rated rom 2500 engine must operate at 2750 rom or above record the engine rom and exhaust system back pressure These results must be entered into the comments section of the Warranty Repair Order 8 The MAXIMUM back pressure limit for both the FD1060 FD1460 engines is 41 In H2O or 3 In Hg or 10 2 kPa If this is exceeded replace the CCM Refer to Figure 3 for applications If the back pressure is below this specification then the CCM is not plugged DEALER WARRANTY CLAIM PROCEDURE In the comment section of the Warranty Repair Order record t
24. self adhesive Isolator Pad E5HZ 9042598 A and attach the pad to the new Spacer obtain locally 11 Check the condition of the original sun visor to roof isolator pads If the new pads are needed replace them with new Isolator Pads F6HZ 9053740 AA 12 Carefully position the sun visor onto the roof and align the attaching bolt holes 13 Flatwashers will be needed as spacers between the sun visor and the roof at the two 2 new attaching screw locations Obtain locally six 6 stainless steel 5 16 or 3 8 x1 8 washers and place three 3 washers between the roof isolator pad and new sun visor at each of the two 2 new attaching locations 14 Install six 6 new Screw and Washer Assemblies N606689 S55 through the original six 6 hole positions 15 Install the two 2 new Screw and Washer Assemblies 606691 5101 through the two 2 new sun visor holes with the new spacer pad assemblies into the new rivet nuts 16 Make sure the sun visor is properly aligned and torque all the fasteners to 22 32 N m 16 24 lb ft Obtain Locally Washer 5 15 Or 3 6 x1 8 Stainless Steel E5HZ 8n42588 A FEHZ 3053740 AA 06 91 5101 Screw And Washer Assembly Nana 12 5309 Rivet Mut MBDBBS9 555 Screw And Washer Assembly 0641955244 Clear Silicone Rubber Sealer OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME 3407154 Replace Current Fastener
25. 000 390000 490000 590000 690000 790000 97 1 Publication Date JANUARY 2 1997 Heater Lack Of Heat In Passenger Compartment Vehicles Equipped With 201060 Engine Article No Cooling System Engine Does Not Reach Operating Temperature Vehicles 07 1 17 Equipped With FD1060 Engine MEDIUM HEAVY TRUCK 1992 97 CARGO SERIES F amp B SERIES L SERIES 1996 97 LOUISVILLE ISSUE There may be a lack of interior cab heat and or the engine may not reach normal operating temperatures This may be caused by the thermostat and deaeration system currently used in FD1060 engines allowing coolant to bypass the thermostat and not reach normal operating temperatures ORIGINAL INSTALLATION FD1060 THERMOSTAT WATER THERMOSTAT LIFT BRACKET WATER OUTLET CONNECTION WATER OUTLET CONNECTION GASKET CYLINDER HEAD Figure 1 Article 97 1 17 ACTION Replace the thermostat and deaeration system The new thermostat will allow for zero bypass of the coolant which should allow the engine to warm up to operating temperature quicker Refer to the following Service Procedure for details SERVICE PROCEDURE Refer to the following sections of the appropriate model year Service Manual for specific component removal and installation procedures that may be necessary to gain access to the engine thermostat Engine Cooling System 03 Air Cleaner Ducting 0 12 Turbocharge Ducting 03A 48 Generator 14
26. 02 Accessory Drive Belts 03A 05 Disconnect the battery ground cable Drain the engine coolant into an appropriate container Remove and or reposition as necessary the air cleaner turbocharger ducting generator accessory drive belts and other components to gain access to the thermostat housing Disconnect the upper radiator hose from the thermostat housing Remove and retain the three 3 thermostat housing attaching bolts Remove and discard the thermostat housing thermostat and gasket Remove and retain the lifting eye Clean the lifting eye and engine block of any sealing material or other debris Refer to Figure 2 NEW ZERO LEAK THERMOSTAT INSTALLATION THIN RING SEAL THICK RING SEAL ENGINE CYLINDER HEAD ATTACHING BOLTS THERMOSTAT HOUSING ZERO LEAK THERMOSTAT mi mm me e E m P 52512511225 Les ENGINE LIFTING EYE Figure 2 Article 97 1 17 FOR THE NEW ZERO LEAK THERMOSTAT BE INSTALLED INTO THE ENGINE A NEW THERMOSTAT HOUSING AND TWO 2 NEW RING SEALS WILL ALSO BE NEEDED NOTE INSTEAD OF THE SINGLE THERMOSTAT GASKET THE ZERO LEAK THERMOSTAT USES TWO 2 SEALS TO PROVIDE A SEAL FOR THE COOLING SYSTEM A THERMOSTAT GASKET IS THEREFORE NOT NEEDED ALSO IT IS NOT NECESSARY TO USE AN RTV OR OTHER SEALER ON THE NEW SEAL RINGS 9 Install the existing engine lifting eye the new thick Seal Ring F7HZ 8255 BA Zero L
27. 14A454 C AA FhHZ 14A454 CBA FBHZ 14A4b4 CU A 14 4 4 FbBHZ 14A4b4 CEA FBHzZ 14A4B54 CF A 14 4 5 2 14 4 14 4 4 14 4 4 2 14 4 4 1 2 14 4 CONNECTOR REPAIR KITS Cont d Service Part Humber Instruction Sheet 1 5 Number fb way white bulkhead connector engine FbHz 14A4b4 CHNA fb way black bulkhead connector engine FbHzZ 14A454 C RA ABS control module 14 454 ABS wheel speed sensor FBHZ 14 454 ABS regulating air valve FRA 14 4464 044 Accelerator position sensor engine FBHZ 14A454 C Y A 1 in line connector OKB9S 4290 1 4305 14318 wire assemblies FBHZ 14A454 C ZA 1 In line connector 10599142091 4305 144 5310 wire assemblies 2 14 4 4 Headlamp switch 2 14 4 4 08 Temperature sensor air intake heater fan control coolant FhbHz 14A454 DC A Accelerator position sensor Cummins electronic DOC and mechanical FB5HZ 144454 D DA engines with electronic transmission Hood mounted turn signal lamps speed sensor manual transmission engine 14 454 speed sensor turbine speed sensor output speed sensor speedometer sensor non electronic automatic transmission tachometer FoR 144464 DF A sensor Neutral sensing switch non electronic automatic transmission FbHz 14 4b4 Di A Clackspring assembly FRA 144464 DHA Gauge
28. 242 or equivalent 3 Position the new Support Bracket F7HZ 2902 BA onto the air compressor and engine bracket 4 Install the four 4 new bolts torquing the bolts to 41 62 N m 30 46 lb ft FFHZ 2902 BA support Bracket N07 470 S36 Bolts 4 Req d OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME Install New Support Bracket Vehicles Equipped With Power steering Install New Support Bracket Vehicles Mot Equipped With 0 6 Hr Power steering DEALER CODING BASIC PART NO CONDITION CODE 2902 OASIS CODES 301000 302000 401000 497000 499000 97 10 Publication Date 12 1997 Loss Of Power Premium Electronic Diesel Engines Intermittent Or Signal From Vehicle Speed Sensor VSS Vehicles Built Through 1 14 97 Malfunction Indicator Lamp MIL Illuminated Fault Codes 31 And 36 For CAT Engine 241 And 242 For Cummins Engine And 54 And 84 For DDC Engine Vehicles Built Through 1 14 97 e Cruise Control Erratic Or Inoperative Vehicles With Premium Electronic Diesel Engine Vehicles Built Through 1 14 97 Article e Lamp Malfunction Indicator Lamp MIL Illuminated With Fault Codes 31 And 36 97 10 12 For CAT Engine 241 And 242 Cummins Engine And 54 And 84 For DDC Engine Vehicles Built Through 1 14 97 e Speedometer Erratic Or Inoperative Vehicles With Premium Electronic Diesel Engine
29. 4 4 4 0 FBHZ 14454 D D 14 4 4 2 14 FoH 144464 D64 4 14 4 4 14 4 14 4 FBHZ 14A464 OLA 14 4 4 14 4 4 FBHZ 14A454 D E A FBHZ 14A454 D5 FBHZ 14A454 DT Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Connector Repair Kit Connector Repair Ki
30. AHZ 17255 A4 Electronic Cluster cpeedometer Tachameter Kilometers FAHZ 17255 BA Electronic Cluster cpeedometer Tachameter Miles with Hour FAHZ 17255 CA Electronic Cluster cpeedometer Tachameter Kilometers with Hour F HZ 17255 DiA Set the speedometer and if applicable tachometer calibration as per the procedure outline in the 1997 Louisville AeroMax Service Manual Section 13 If needed the speedometer repair can be verified by performing the following Speedometer Heat Test SPEEDOMETER ASSEMBLY HEAT SENSITIVITY HEAT SOAK TEST NOTE TESTS MUST BE PERFORMED WITH THE SPEEDOMETER ASSEMBLY COMPLETELY INSTALLED PERFORMING THE HEAT SOAK BREAKDOWN TEST WITH THE ASSEMBLY REMOVED WILL BE INEFFECTIVE 1 Clear any active inactive codes from the ECM Start the engine turn on instrument panel lights set fan to high speed heat to full hot position and vent ducts to floor position With windows closed bring the engine and cab to full operating temperature After allowing the speedometer head and instrument panel assembly to fully heat soak speedometer operation and vehicle speed signal output to the ECM can be verified by road testing or dynamometer testing The test may also be performed by operating the transmission in high gear at engine idle with the transmission coupling shaft removed With instrument panel lights on and the heater on high as per Step 1 of this test the engine should not derate speedometer become inoper
31. Back Of Cab Vehicles Vehicles Built From 10 7 96 Through 3 13 97 97 23 16 MEDIUM HEAVY TRUCK 1997 LOUISVILLE ISSUE The hood may separate at the inner hood reinforcement bond on some vehicles This may be caused by the bonding design between the hood center rear reinforcement and the hood side reinforcement ACTION Repair the hood by securing the hood center rear reinforcement to the hood side reinforcements Refer to the following Service Procedure for details SERVICE PROCEDURE 1 Open and inspect the inside of the hood at the hood center rear reinforcement to the hood side reinforcement bond locations Figures 2 and 3 for 113 and 122 Bumper to Back of Cab BBC vehicles and Figures 4 and 5 for 101 BBC vehicles Inspect both right and left side bonds SEAM LOCATION POSSIBLE HOOD REINFORCEMENT SEPARATION NEW RIVET LOCATIONS VIEW LEFT INSIDE OF VIEW A CROSS SECTION VIEW OF HOOD NEW RIVET CENTER REAR REINFORCEMENT LOCATIONS AND HOOD OUTER SHELL FRONT OF VEHICLE Lip TOP 22225 W 108 5mm 88 2mm Figure 2 Article 97 23 16 SEAM LOCATION OF POSSIBLE HOOD REINFORCEMENT SEPARATION NEW RIVET LOGATIONS E 2 VIEW OF RIGHT INSIDE OF HOOD VIEW B CROSS SECTION VIEW HOOD NEW RIVET FORCEMENT LOCATION AND HOOD OUTER SHELL FRONT OF VEHICLE Figure 3 Article 97 23 16 NEW RIVET LOCATIONS VIEW OF LEFT INSIDE OF HOOD 101
32. CE EQUIPPED WITH THE ORIGINAL FULLY ROUND PIN THE ALIGNING FEATURE OF THE NEW ISOLATOR MUST BE REMOVED THIS CAN BE DONE BY CUTTING THE RUBBER WEDGE OUT USING A KNIFE NEW SUPPORT PINS ARE NOT NEEDED NOTE PROPER POSITIONING OF THE NEW REAR MOUNTS ISOLATORS 15 VERY IMPORTANT ON FD1060 ENGINES THE NEW ISOLATORS MUST BE INSTALLED WITH THE LARGE VOID ON TOP ON FD1460 ENGINES THE ISOLATORS MUST BE INSTALLED WITH THE LARGE VOID ON THE BOTTOM 4 sure the new isolators are oriented correctly then install the new isolators onto the pins NOTE TO PREVENT THE POSSIBLE ROTATION OF THE NEW ISOLATOR NEW CAPS ARE NEEDED THE NEW CAP HAS A SETSCREW BUILT IN THAT LOCKS THE ISOLATOR IN PLACE 5 Slowly lower the engine onto the revised isolators and remove the service jack and wood block 6 Install a new cap onto each revised isolators 7 Install the existing isolator cap retaining bolts washers and new Nuts 34989 52 Torque the bolts to 102 142 N m 75 105 Ib ft PART NUMBER PART HAME Fr Hz BLI38 AA Rear Engine Mount 2 F HZ BAUES AA Rear Engine Mount 2 Req d 34989 52 Mut 1 2 13 Hex Lock 4 Req d OTHER APPLICABLE ARTICLES 95 23 15 WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME Replace Rear Engine Mounts Cargo With FDITUBU Engine Replace Rear Engine Mounts Cargo With FO1460 Engine Replace Rear Engine Mou
33. CLES SHOULD BE REVIEWED AND IF APPLICABLE PERFORMED ON VEHICLES THAT HAVE CONCERNS WITH WHITE SMOKE AND OR ENGINE CAB HEATING CONCERNS THE TWO 2 TSB ARTICLES ARE 1 FD1460 ENGINE 96 19 11 ENGINE THERMOSTAT SHIM KIT AND 2 FD1060 ENGINE 97 1 17 ZERO LEAK THERMOSTAT AND DEAERATION CHECK VALVE OTHER APPLICABLE ARTICLES 96 19 11 97 1 17 WARRANTY STATUS INFORMATION ONLY OASIS CODES 403000 499000 97 5 Publication Date 3 1997 Front End Accessory Drive Belt FEAD FEAD Belt May Wear And Or Come Off Article No Vehicles Equipped With FD1460 Engine Built Through 12 96 97 5 18 MEDIUM HEAVY TRUCK 1997 LOUISVILLE ISSUE The Front End Accessory Drive FEAD belt may wear and or come off on some vehicles equipped with an FD1460 engine Delco generator and air conditioning This may be caused by the generator and air conditioning support bracket allowing the generator drive pulley to be misaligned with the other pulleys in the FEAD system ACTION Replace the generator and air conditioning bracket with a revised bracket The revised bracket should keep the pulleys in alignment to reduce the possibility of FEAD belt wear and or roll off Refer to the following Service Procedure for details SERVICE PROCEDURE Refer to Page 12 03A 54 of the 1997 Louisville AeroMax Service Manual for a sketch of the bracket The bracket Is Item 10 1 Disconnect the negative battery c
34. E FAN CONTROL RELAY 21 I8 THERE GROUND ON F F PIN 1 OR 2 REMOVE PIN REMOVE REMOVE PIN 28 135 C171 IS C110 KOER 15 THERE GROUND ON R 21 THERE POWER 21 THERE POWER R 21 1 27 PIN 1 OR 2 F P PIN 1 OR 27 Figure 4 Article 97 22 18 CHART D FAN STAYS ENGAGED HORTON CLUTCH 15 836 POWERED AT THE FAN CONTROL SOLENOID CHECK FAN CONTROL SOLENOID AND ITS AIR SUPPLY Figure 5 Article 97 22 18 REMOVE THE FAN CONTROL RELAY R 21 DOES THE FAN STOP JUMPER PINS 3 AND 6 AT FUSE PANEL LOCATION 21 DOES THE FAN START CHART STAYS ENGAGED BENDIX AND KYSOR FAN CLUTCHES VOLT 67 BETWEEN THE SOLENOID AND GROUND I8 THE VOLTAGE GREATER THAN 0 27 Figure 6 Article 97 22 18 REMOVE THE FAN CONTROL RELAY R 21 JUMPER BETWEEN PINS 3 AND 5 AT THE F P DOES THE FAN STOP KOER i8 THERE POWER AT F P PIN 3 OR 6 FOR 21 REPAIR IN CKT 517 CHECK FUBE 12 AND LOCATION OF 517 AT 21 CHART F FAN STAYS ALL FAN CLUTCHES REMOVE CONTROL RELAY R 21 THERE POWER FIP PIN 1 OR 27 KOER BACK PROBE PIN AT C135 GROUND PRESENT Figure 7 Article 97 22 18 REMOVE FAN CONTROL RELAY 9 21 KOER IS THERE GROUND ON F P PIN 1 OR 27
35. GINE MOUNT ISOLATOR FOR L F CF SERIES WITH FD1060 OR FD1460 ENGINE LARGE VOID PIN BRACKET MOUNTED ON ENGINE FD1460 ISOLATORS MUST BE INSTALLED WITH THE LARGE VOID DOWN O CLOCK POSITION Figure 2 Article 97 1 18 LARGE VOID PIN BRACKET MOUNTED ON FRAME FD1060 ISOLATORS MUST BE INSTALLED WITH THE LARGE VOID UP 12 O CLOCK POSITION FD1460 ENGINE SHOWN VEHICLES BUILT BEFORE 10 15 96 ML S HEW WITH SETSCHEW N i NEW ISOLATOR WITH RUBBER WEDGE REMOVED TO FIT EXISTING PIN lt gt FD1460 ENGINE SHOWN VEHICLES BUILT AFTER 10 15 96 NEW PIN WITH A FLAT NEW ISOLATOR ISOLATOR WITH RUBBER ALIGNING WEDGE 4871 L _ _ _ _ E Figure 3 Article 97 1 18 1 Remove the bolts nuts and washers that retain both the right and left side rear engine mount isolator caps 2 Carefully raise the rear of the engine using suitable service jack and a wood block placed under the transmission The engine should only be raised enough to unload the rear engine mounts isolators and to allow their removal 3 Remove and discard the existing rear mounts isolators NOTE THE REVISED ISOLATORS HAVE A SELF ALIGNING FEATURE BUILT INTO THEM IT IS A RUBBER WEDGE THAT FITS ONTO THE CORRESPONDING FLAT OF THE NEW SUPPORT PIN THIS FEATURE AIDS THE ASSEMBLY PROCESS AND IT IS UTILIZED ON VEHICLES BUILT AFTER 10 15 96 ON VEHICLES ALREADY IN SERVI
36. HICLES EQUIPPED A WITH PREMIUM DIESEL ENGINE BUILT BEFORE 10 7 96 THIS TSB DOES NOT APPLY TO CAT 3126 ELECTRONIC ENGINES ADDITIONAL SERVICE INFORMATION ON FAN CLUTCH OPERATION CAN BE FOUND IN OTHER TECHNICAL SERVICE BULLETINS IN SERVICE MANUALS AND THE ELECTRICAL AND VACUUM TROUBLESHOOTING MANUAL EVTM OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS INFORMATION ONLY OASIS CODES 208000 402000 499000 97 24 Publication Date NOVEMBER 24 1997 Exhaust System Flex Pipe Which Attaches The Turbocharger Outlet Pipe Article No Crack Vehicles Equipped With Detroit Diesel Engine Built Through 12 97 07 24 31 MEDIUM HEAVY TRUCK 1996 98 LOUISVILLE ISSUE The exhaust flex pipe that comes from the turbocharger outlet may crack on some vehicles equipped with a Detroit Diesel engine This may be caused by the existing pipe being too rigid to compensate for normal vibrations and movements of the exhaust system ACTION Modify the exhaust system and install a longer flex pipe The longer flex pipe should reduce the possibility of cracking Refer to the following Service Procedure for details SERVICE PROCEDURE 1 Remove and discard the existing exhaust system flex pipe and clamps 2 Cuta total of 76mm 3 from the existing turbocharger outlet pipe and or muffler inlet pipe extension at the flex pipe connection Refer to Figure 1 LOUISVILLE AEROMAX WITH DDC ENGINE AND HORIZONTAL MUFFLER SHOW
37. KE COMPRESSOR TO THE FRONT GEAR HOUSING ARE SOUND COATED WITH LOCTITE AND TORQUED TO THE FOLLOWING SPECIFICATIONS AIR COMPRESSOR MOUNTING STUDS 60 95 N m 44 70 LB FT AND AIR COMPRESSOR ATTACHING NUTS 60 95 N m 44 70 LB FT THE AIR BRAKE COMPRESSOR REAR SUPPORT BRACKET MUST ALSO BE MOUNTED PROPERLY AND ITS FASTENERS COATED WITH LOCTITE AND TORQUED PROPERLY ADDITIONAL INFORMATION REGARDING THE AIR BRAKE COMPRESSOR CAN BE FOUND IN THE FOLLOWING TSBs 94 9 18 95 15 17 AND TSB 97 10 11 PART HUMBER PART HAME FTAESEDE AA OTHER APPLICABLE ARTICLES 94 9 18 95 15 17 97 10 11 WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME 371144 Replace Air Brake Compressor Mounting Gasket Refer To SLITS Manual DEALER CODING BASIC PART NO CONDITION CODE 2902 OASIS CODES 301000 302000 401000 497000 499000 97 12 Publication Date JUNE 9 1997 Turn Signal Turn Signals Cancel Shut Off When Steering Column Is Jarred Article No Vehicles Equipped With Manual Cancel Turn Signal Switch Built 11 95 Through 3 97 97 12 14 MEDIUM HEAVY TRUCK 1996 97 AEROMAX LOUISVILLE ISSUE The turn signal switch may self cancel when the steering column and or vehicle is jarred This may be caused by insufficient detent within the switch for the turn signal switch lever ACTION Replace the turn signal switch with a revised Turn Signal Switch F7HZ 13B302 DA whi
38. MATICS and Cummins electronic engines with Kysor fan clutch Figure 13 CATICUMMINS WITH KYSOR CLUTCH NOTE AAG HIGH PRESSURE SWITCH ES NORMALLY OPEN ILE IT CLOSES WITH HIGH PRESSURE FAM OVERRIDE SWITCH Hi NORMALLY LE IT OLOSES TO ACTIVATE THE OVERRIDE Figure 13 Article 97 22 18 and Cummins electronic engines with Horton fan clutch Figure 14 NOTE HIGH PRESSURE SWITCH IS NORMALLY OPEN LE CLOSES WITH HIGH PRESSURE FAN OVERRIDE SWITCH 13 NORMALLY DPEN LE IT CLOSES TO ACTIVATE THE OVERRIDE Figure 14 Article 97 22 18 Detroit Diesel electronic engines with Kysor fan clutch Figure 15 DDC 60 WITH FAN CLUTCH NOTE HIGH PRESSUAE BWITCH NORMALLY OPEN 0E T CLOSES WITH HIGH PRESSURE FAN OVERRIDE SWITCH NORMALLY OPEN LE IT CLOSES TO ACTIVATE THE OVERPIOR Figure 15 Article 97 22 18 e X Detroit Diesel electronic engines with Horton fan clutch Figure 16 NOTE HIGH PRESSURE SWITCH IS NORMALLY OPEN IT CLOSES WITH HIGH PREBGBURME DVERHIDE SWITCH 18 NORMALLY OPEN LE IT CLOSES TO ACTIVATE THE GVERAIDEL Figure 16 Article 97 22 18 OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS INFORMATION ONLY OASIS CODES 208000 402000 499000 97 23 Publication Date NOVEMBER 10 1997 Hood Inner Hood Reinforcement Bond Separation 101 113 And 122 Inch Article Bumper To
39. N ORIGINAL INSTALLATION TURBOCHARGER OUTLET PIPE SY MUFFLER INLET FLEX PIPE PIPE EXTENSION AND CLAMPS TO BE REPLACED 76mm 76mm 37 37 seng TOTAL OF 76mm 37 OF PIPE MUST BE REMOVED FROM THE TURBOCHARGER OUTLET PIPE AND OR MUFFLER INLET PIPE EXTENSION TO ACCOMODATE THE NEW LONGER FLEX PIPE 5328 Figure 1 Article 97 24 31 THE MOUNTING AND ALIGNMENT THE EXHAUST SYSTEM IS CRITICAL THE DURABILITY OF THE FLEX PIPE THE ENTIRE EXHAUST SYSTEM SHOULD BE CHECKED AND REPAIRED IF NECESSARY PRIOR TO INSTALLING THE NEW FLEX PIPE 3 Install the new Flex Pipe DOHZ 5B286 B and new wide band Clamps F2HZ 5A231 C 4 Torque the clamps to 61 81 N m 45 60 lb ft PART NAME DOHZ 5B285 B Flex Pipe 2 5 231 Clamps 2 Req d OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME 9 2431 Repair Exhaust Horizontal 1 4 Hrs 3424316 Repair Exhaust Vertical 1 3 Hrs DEALER CODING BASIC PART CONDITION CODE 58286 OASIS CODES 403000 497000
40. NTO THE ENGINE THEN DURING INSTALLATION THE UPPER BOLT WILL HAVE TO BE THREADED INTO PLACE BEFORE THE STARTER MOTOR CAN BE FULLY SEATED ONTO THE BELLHOUSING NOTE WHEN INSTALLED ON THE ENGINE THE SOLENOID OF THE NEW STARTER MOTOR IS POSITIONED BELOW THE NEW STARTER ON SOME VEHICLES IT MAY BE NECESSARY TO ADJUST THE ROUTING AND OR CLIPPING OF THE STARTER MOTOR WIRING HARNESS TO PROVIDE SUFFICIENT LENGTH FOR INSTALLATION AND ENSURE THE WIRING 1 NOT STRESSED DURING ENGINE OPERATION PART NUMBER PART FYHZ 11002 E4 starter Manual Transmission And Automatic Transmission EXCEPT AT 545 FFHZ 11002 F starter Vehicles With 41 545 Automatic Transmission OTHER APPLICABLE ARTICLES 94 26 13 WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME Replace Starter Motor F amp B Series Alligator Hood Replace Starter Motor amp B Series Tilt Hood Replace Starter Motor Cargo DEALER CODING BASIC PART CONDITION CODE 11002 OASIS CODES 499000 601300 603300 97 4 Publication Date FEBRUARY 17 1997 FEAD Belt High Wear And Or Comes Off Of The Drive Pulley Vehicles Built From Article No 4 1 92 Through 6 1 96 With FD1060 Engine 97 4 11 MEDIUM HEAVY TRUCK 1992 97 SERIES F amp SERIES SERIES This TSB article is being republished in its entirety to revise the part number of the Idler Pulley Support Plate ISSUE T
41. PAIR IS VERY IMPORTANT THAT THE OVERFLOW CHECK VALVE FUEL PRESSURE VALVE BE RETURNED WITH THE PUMP THIS WILL ENSURE THAT THE DSD WILL BE ABLE TO MAKE THE PROPER DIAGNOSIS OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS INFORMATION ONLY OASIS CODES 404000 97 7 Publication Date 31 1997 Article No Wiring Wire Harness Ground Intermittent Or Open g7 7 17 MEDIUM HEAVY TRUCK 1996 97 AEROMAX LOUISVILLE ISSUE Intermittent or complete loss of the electrical system may be experienced on some vehicles This be due to the improper seating of the single terminal ground system connectors which are used to connect the 14290 wire harness to the 14289 or 14305 wire assemblies ACTION Gain access to the ground system connectors and fully seat the connections Refer to the following Service Procedure for details SERVICE PROCEDURE 1 Raise the hood to gain access to the left inner fender splash panel 2 Loosen the fender splash panel forward retaining nut DO NOT REMOVE THE NUT 3 While supporting the fender splash panel remove the remaining five 5 nuts and then carefully remove the fender splash panel 4 Locate the ground system single terminal connectors Figure 1 that connect the 14290 wire assembly to the 14289 or 14305 wire assemblies GROUND SYSTEM CONNECTIONS ies VEHICLE Figure 1 Article 97 7 17 5 he two 2 ground circuits are tagged gre
42. PROCEDURE Remove the two 2 single V belts from the generator and engine pulleys Refer to the appropriate year Louisville AeroMax Service Manual Page 03C 05 1 for removal procedures 2 Check the conditions of the drive pulleys Make sure they are free of nicks debris etc 3 Install the new banded belt over the generator pulleys and engine pulleys Be sure the belts are properly seated in the pulleys 4 Tighten the generator adjusting bolt so that the belt tension on the new banded belt is within 183 203 N m 135 150 lb ft PART NUMBER PART NAME 85 20 4 Banded W Belt OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME SOSA Replace senerator Belts DEALER CODING BASIC PART CONDITION CODE 9620 3 OASIS CODES 203000 203100 205000 499000 97 10 Publication Date 12 1997 Air Brakes Oil Leak At Air Brake Compressor Vehicles Built Through 4 1 97 Equipped With FD1460 Engine And Air Brakes Article No Leak Oil Leak At Air Brake Compressor Vehicles Built Through 4 1 97 Equipped 97 10 11 With FD1460 Engine And Air Brakes MEDIUM HEAVY TRUCK 1993 97 SERIES F SERIES L SERIES ISSUE The engine may leak oil at the air brake compressor on some vehicles This may be caused by insufficient rear support of the air brake compressor ACTION Replace the rear air brake comp
43. Part Number Instruction Sheet 1 5 Number 2 14 4 FBHZ 14A454 BB 2 14 4 FbBHZ 14A4B54 BD FbHZ 14A4b4 BE FBHzZ 144A454 BF FbHzZ 14A4Bb4 Bi5 14 4 4 14 454 Windshield wiper control module Signal Stat multi function switch audio FbHA14 4464 BL4 amplifier output Aerodynamic headlamps Ether valve solenoid heated seat Windshield washer pump motor 23 in line connector 1409124501 wire assembly Switches low air pressure park brake cruise dropout low ail pressure Engine fan control module Cummins 111 14 3306 and 1460 stoplamp switch air dryer Multi function tum emergency signal switch UT Fuel sender fog road lamps Push button start switch J pin trailer connector 31 pin in line connector 15525 wire assembly 31 in line connector 15525 wire assembly Tail lamp compressor CAT 3306 F 01460 Idle validation switch Cummins DDC engines otart interlack switch Exhaust brake clutch switch Alr intake solenoid temperature senders engine ail transmission oil water rear axle Wiper control module Signal Stat F ord fb way white bulkhead connector cab fb way black bulkhead connector cab 7 14 4 FBHZ 14A454 BEM 7 14 FbHZ 14A4b4 B 5A FBHzZ 144454 B T FbBHZ 14A4Bb4 BlIA 2 14 4 2 14 4 2 14 4 FBHZ
44. S CONTINUITY BETWEEN C108 PRESENT BETWEEN C108 PIN 2 AND C135 PIN 2 AND C171 PIN 17 PIN T Figure 10 Article 97 22 18 CHART J FAN WILL NOT ENGAGE WITH OVERRIDE SWITCH REPAIR GROUND CKT CHECK PARK BRAKE SWITCH Figure 11 Article 97 22 18 REMOVE AG HIGH PRESSURE RELAY 9 15 DOES FAN ENGAGE KOER 8 THERE POWER AT FP PIN 1 OR 2 FOR R 157 APPLY PARKING DISCONNECT A C HIGH REPAIR OPEN IN CKT PRESSURE SWITCH AND TOGGLE 517 CHECK FUSE 12 FAN OVERRIDE SWITCH AND LOCATION OF I8 THERE GROUND ON 617 AT R 15 15 PIN 1 OR 27 REINSTALL 15 KOER IS THERE POWER ON PIN 1 OR 2 OF OVEARIDE SWITCH DISCONNECT REPAIR OPEN IN PARK BRAKE SWITCH CKT 162 CHECK 13 THERE POWER ON OVERRIDE CKT 1627 SWITCH CHART FAN WILL ENGAGE WITH HIGH A G REFRIGERANT PRESSURE REMOVE HIGH PRESSURE A 15 DOES FAN ENQAQE DISCONNECT FAN OVERRIDE SWITCH AND JUMPER 02015 PINS 2 AND 3 DOES LIGHT COME ON SWITCH AND JUMPER C2048 PINS 1 AND 2 DOES LIGHT COME ON IS THERE POWER R 15 FP PIN 1 OR 27 CONNECT TEST LIGHT BETWEEN 15 PINS 1 AND 2 TOGGLE FAN OVERRIDE SWITCH AND SET PARKING BRAKE KOER VOLT DROP CKT 57 BETWEEN BRAKE SWITCH AND GROUND IS VOLTAGE GREATER REPAIR OPEN ON GROUND CKT 57 Figure 12 Article 97 22 18 WIRING SCHE
45. TO EACH FRAME RAIL CARE SHOULD BE TAKEN WHEN PERFORMING THE DRILLING OPERATION TO PREVENT DAMAGE TO THE FRAME AND SURROUNDING COMPONENTS REFER TO THE FORD BODY BUILDERS LAYOUT BOOK FOR ADDITIONAL INFORMATION REGARDING FRAME RAIL MODIFICATIONS 1 Verify the concern NOTE INSPECT THE VEHICLE TO DETERMINE IF A MODIFICATION HAS BEEN MADE TO THE FRONT SUSPENSION OF THE VEHICLE SOME VEHICLES COMPLETED AS DUMP TRUCKS HAVE ADDITIONAL PUSHER OR TAG REAR AXLES AND TO LEVEL OUT THE FRAME SPACERS OR ADDITIONAL SPRING LEAVES MAY HAVE BEEN ADDED TO THE FRONT SPRINGS THE MAXIMUM ALLOWABLE SPRING PACK THICKNESS IS 134 1mm 5 28 WITH THE CASTER WEDGE INCLUDED NEW SPRINGS HAVE A CASTER WEDGE INCLUDED IN THE SPRING PACK IF THE SPRING PACK IS THICKER THE EXTRA LEAVES MUST BE REMOVED 2 Balance the front tires 3 Check and correct if necessary front wheel runout if it exceeds 2 28mm 0 090 4 Refer to the following chart item BEE 3 EES 5 6 e 5212 Figure 1 Article 97 19 21 Figure 2 Article 97 19 21 Des _ 1 Puman Arm Right Sie 2 iman Amn et Si 2 ES d FRONT AXLES ONLY FRONT OF VEHICLE wig ir TB 5214 A Figure 3 Article 97 19 21 HOLE PATTERN UPPER SHOCK BRACKET et FRONT OF FRAME 15 350 141 90mm 5 5877 50 30mm 1 980 ah aD 43 10mm 11 697 3 HOLES REQUIRED 13 87mm 0 5467 DIA 13 36mm 0 526
46. Window Window Difficult Roll Or Down MEDIUM HEAVY TRUCK 1975 96 L SERIES ISSUE The windows may be hard to roll up and or down This may be caused by corrosion buildup within the window regulator mechanism ACTION Replace the window regulator with a revised regulator which has added a corrosion coating on the regulator to reduce the possibility of corrosion Refer to the appropriate L Series Service Manual Section 01 11 for removal and installation procedures PART NUMBER PART NAME FSH 0023200 44 Regulator Right PSH 00 23 201 4 8 Regulator Left OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME 9 154 Replace Window Regulator Both Sides 1 3 Hrs g7 1529A Replace Window Regulator One Side 0 8 Hr DEALER CODING BASIC PART NO CONDITION CODE 8023200 OASIS CODES 102000 110000 97 15 Publication Date JULY 21 1997 MEDIUM HEAVY TRUCK 1996 97 LOUISVILLE 1996 98 SERIES F amp SERIES SERIES ISSUE A brake squealing noise and or vibration may be heard or felt on some vehicles traveling at low speeds with a light load This may be caused by the brake lining material ACTION Replace the brake linings The new linings have been revised with a different material to reduce the possibility of noise and or vibration at low speeds with a light lo
47. able 2 Remove or reposition any components as necessary to gain access to the bracket NOTE REMOVAL AND INSTALLATION PROCEDURES FOR THE AIR CONDITIONING COMPRESSOR CAN BE FOUND IN SECTION 12 03A AND FOR THE GENERATOR SECTION 14 02B OF THE 1997 LOUISVILLE AEROMAX SERVICE MANUAL 3 Remove the bracket from the engine Discard the bracket but retain the four 4 attaching bolts 4 Position the revised Bracket F7HZ 19D626 AA onto the engine and torque the attaching bolts to 22 33 N m 16 24 lb ft 5 Reinstall all components that were previously removed 6 Reconnect the negative battery cable PART NUMBER PART NAME FTHZ 19D826 AA OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME 4705104 Replace Generator Bracket 1 5 Hrs DEALER CODING BASIC PART NO CONDITION CODE 190626 OASIS CODES 203100 208200 499000 97 6 Publication Date 17 1997 e Hard Starting Possible Plugged Catalytic Converter Muffler CCM Vehicles Built After 11 29 93 Equipped With 1994 Emission Level FD1060 Or FD1460 Diesel Engine Lack Of Power Possible Plugged Catalytic Converter Muffler CCM Vehicles Built After 11 29 93 With 1994 Emission Level FD1060 Or FD1460 Diesel Engine Catalytic Converter Muffler CCM Diagnostic Procedures And Service Parts List Article No Vehicles Built After 11 29 93 Equipped With 1994 Emissio
48. ad Refer to the appropriate model year Service Manual for removal and installation procedures NOTE THE BRAKE LININGS LISTED IN THIS ARTICLE ONLY APPLY TO VEHICLES EQUIPPED WITH Q PLUS BRAKES FOLZ 2010 AA Brake Shoes 15x4 SK Axle POH Z 2010 DA Brake Shoes 15 4 10 13 Axle 2018 Brake Shoes 1B 5x5 12 13 Axle FDC 2016 DA Brake Shoes 15 5x5 114 66 Narrow Axle 2 2018 Brake Shoes 15 5xb 14 6K Wide Axle FOHA 2016 FA Brake Shoes 16 56 16 18K Axle POH 2210 44 Brake Shoes 16 5 21K Axle 2218 Brake Shoes 16 587 17 5 19 Single 34K 40K Tandem Axle 2007 Lining Kit 1554 Ok Axle 2007 Lining Kit 15x4 10 13 Axle 2007 Lining Kit 15 5x5 12 136 Axle FoH 400 DA Lining Kit 16 525 14 6 Narrow Axle FOHZ ZU07 EA Lining Kit 15 5xb 14 6K Wide Axle POH Z 204 FA Lining Kit 15 5xb 16 186 Axle 2007 Lining Kit 16 537 21K Axle 2007 A Lining Kit 15 5x 17 5 19K Single a4kK 40K Tandem Axle OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME 3715504 Replace Brake Linings Refer To SLTS Manual DEALER CODING BASIC PART CONDITION CODE OASIS CODES 301000 702000 702100 702200 703000 97 16 Publication Date AUGUST 4 1997 Exhaust Muffler Inlet Pipe Cracked Vehicles
49. advised if the failed component is still covered within the Bosch warranty program The DSD will then be able to submit for payment the necessary repairs through the Bosch warranty system In order for the DSD to file a warranty claim certain information regarding the vehicle and the failed Bosch component is required This information should be provided to the DSD when the component is brought in for service The required information 15 Customer complaint engine driveability concern Engine make and model Engine serial number Vehicle make and model e X Vehicle delivery date or warranty start date e Failed component part number e Failed component vehicle miles or hours of operation e Failure date vehicle repair date Bosch provides a form entitled Request for Warranty Repair that highlights the required information It is available from the local DSD and is a useful tool to ensure all the required information is provided In some cases the Bosch warranty may have expired however vehicle may still be covered under the Ford warranty In these cases the failed component should still be repaired at a Bosch DSD and a claim for the cost submitted to Ford Motor Company following the procedure listed in the Ford Warranty and Policy Manual Additional questions regarding Bosch warranty policies and procedure should be directed to your local Bosch DSD NOTE IF THE FUEL INJECTION PUMP IS RETURNED TO DSD FOR DIAGNOSIS AND OR RE
50. an intermittent or no signal condition is present carefully inspect the speedometer head to 14401 wire assembly connector CAUTION DO NOT ATTEMPT TO PROBE THE SPEEDOMETER HEAD TO WIRE ASSEMBLY CONNECTOR FROM THE FRONT b Inspect the connector for deformed terminals by looking into the front of the connector c Ifthe connector hard shell or any terminals show signs of damage replace the connector with the connector assembly found in Connector Kit F7HZ 14A464 AB 4 opeedometer Head Loss Of Digital Output Signal To ECM Erratic Or Inoperative Speedometer a Check the vehicle production date If the production date is earlier than 1 14 97 remove the speedometer assembly b Check the speedometer head for a tag showing alert number 10695533 Electronic cluster gauges will have the alert sticker placed on the metal housing of the tachometer Individual case gauges will have the alert sticker on the plastic housing of the gauge If no alert sticker is found and the engineering number is one of the following e F HI 17255 AB e F HI 17255 BB e F HI 17C290 AB e F HI 17C290 BB F HI 17C290 CB F HI 17C290 DB replace the speedometer assembly Refer to the following Speedometer Assembly Description Chart for part number SPEEDOMETER ASSEMBLY DESCRIPTION RPO Case 5 Speedometer Miles FAHZ 172 255 AB Case 5 Speedometer Kilometers FY HZ 17255 BB Electronic Cluster cpeedometer Tachameter Miles F
51. ative erratic or the check engine light come on during the test Verify that the ECM has not logged a loss of vehicle speed signal fault code to complete the test PART NUMBER PART NAME FRH 14 4464 46 Connector Kit FRHZ 144464 DEA Connector Kit F HZ 172255 AB speedometer Assembly F HZ 17255 BB speedometer Assembly 1 7 255 speedometer Assembly FzZHz 17255 BA speedometer Assembly F Hz 17255 CA Speedometer Assembly F Hz 17255 DA Speedometer Assembly OTHER APPLICABLE ARTICLES 97 10 13 WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE Install Vehicle Speed Sensor v S3 Or Electronic Control Module ECM Connector Kit Replace speedometer 15 Connector DEALER CODING BASIC PART NO CONDITION CODE 17255 OASIS CODES 204000 204200 205000 609000 610000 612000 614000 698298 97 10 Publication Date 12 1997 Article No Wiring Electrical Connector Kit Availability 97 10 13 MEDIUM HEAVY TRUCK 1996 97 AEROMAX LOUISVILLE This TSB article is being republished in its entirety to include the latest level parts for repairing the Speedometer and Tachometer ISSUE Kits for repairing wire harness connectors are now available for service These kits will save the cost of replacing an entire wiring harness when only the connector needs replacing ACTION If connector repairs are required and you desire to purchase a kit s refer to the Connector
52. blication Date JUNE 23 1997 Article No Heater Lack Of Heat In Cab Vehicles With FD1060 Engine Built Through 12 5 96 97 13 24 MEDIUM HEAVY TRUCK 1997 LOUISVILLE ISSUE There may be insufficient cab heat on some vehicles his may be caused by the hot water supply being Incorrectly routed from the radiator ACTION Relocate the hot water supply to the engine block to provide sufficient cab heat Refer to the following Service Procedure for details SERVICE PROCEDURE NOTE COMPONENTS WHICH ARE THREADED WITH AN NPT SHOULD NOT BE REUSED ONLY COMPONENTS WITH NEW PIPE THREADS AND SEALANT SHOULD BE USED IN THE MODIFICATION DESCRIBED IN THIS TSB ARTICLE 1 2 Drain engine coolant to a level just below the top of the water jacket Remove the heater core supply hose lower hose from the heater core and current valve location on the upper radiator pipe Remove heater control valve and all attached elbows and fittings from the upper radiator pipe and install a new Plug obtain locally into the boss where the valve was located Remove all components and plugs from the two 2 water jacket penetrations near the top forward portion of the engine immediately before the thermostat housing Assemble the Heater Water Inlet Tube Assembly F2HZ 18696 C T fitting obtain locally Pipe Connector 5 8x1 2 obtain locally Heater Water Control Valve Assembly FOHZ 18495 A Elbow 45 Degree obtain locally and Pipe Conne
53. ch Release Lever TB 5066 A jj SGS S _ __ _ _ _ __ _ __ _Q Q gt __ _ _ _ __ _ _ Q_ _ _ _ _ _ _ _ __ _ _ _ Figure 2 Article 97 12 15 NOTE TO ENSURE PROPER OPERATION IT 1 VERY IMPORTANT THAT THE STANDARD PARTS PROVIDED IN THIS TSB BE USED TO INSTALL THE NEW ELASTOMERIC ROD 1 Remove the clutch rod assembly from the vehicle a Remove the nut at the top of the rod retaining the clutch rod to the clutch pedal shaft and lever Discard the nut NOTE BEFORE REMOVING THE CLUTCH ROD ASSEMBLY FROM THE CLUTCH ROD LEVER AT THE TRANSMISSION BE SURE TO NOTICE ITS ORIENTATION THE CLUTCH ROD WILL EITHER BE INBOARD BETWEEN THE CLUTCH LEVER AND THE TRANSMISSION OR OUTBOARD OF THE CLUTCH LEVER OPPOSITE THE TRANSMISSION BETWEEN THE CLUTCH LEVER AND THE FRAME b Remove the nut at the bottom of the rod retaining the clutch rod to the clutch release lever Discard the nut c Remove the clutch rod assembly from the vehicle 2 Secure the clutch rod in a vise so that the lower ball stud the ball stud that attaches to the clutch release lever is accessible Refer to Figure 3 for Steps 3 and 4 of the Service Procedure ORIGINAL BALL STUD AND NEW ELASTOMERIC ROD END CUT THE BALL STUD SHANK HERE USE CARE TO PREVENT DAMAGE TO THE CLUTCH ROD THREADS MEASURE AND NOTE THIS DIMENSION INSTALL THE NEW ELASTOMERIC ROD END SO THAT THIS DIMENSION 15 MAINTAINED Description Mem 1 Clut
54. ch has an improved detent Refer to Section 17 01 of the appropriate year Louisville AeroMax Service Manual for removal and installation procedures NOTE THE NEW TURN SIGNAL SWITCH HAS A LONGER WIRING HARNESS WHICH NOW CONNECTS DIRECTLY TO THE WIPER MOTOR REFER TO FIGURE 1 WITH THE NEW SWITCH THE JUMPER HARNESS THAT WAS USED TO CONNECT THE PREVIOUS SWITCH TO THE WIPER MOTOR IS NO LONGER NEEDED AND SHOULD BE REMOVED AND DISCARDED UY 2 B TZ Le uv aD Description New Signal Stat Tum Signal Multl functlon Switch Steering Column Clutch Pedal New Switch Wiring Hamess this hamess is part of the Signal Stat Switch and it connects directly into the Windshield Wiper Module Windshield Wiper Module Figure 1 Article 97 12 14 PART NUMBER PART NAME F HZ 13B302 D A Turn Signal Switch OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME 3712144 Replace Turn Signal Switch 0 3 Hr DEALER CODING BASIC PART CONDITION CODE 13341 OASIS CODES 201000 201200 203000 97 12 Publication Date JUNE 9 1997 NOISE Rattling Noise In Clutch Linkage Vehicles With Standard Transmission And 113 Inch Or 122 Inch Bumper To Back Of Cab Length Article No e CLUTCH Rattling Noise In Clutch Linkage Vehicles With Standard T
55. chRod 2 Original Ball Stud 3 Clutch Release Lever 4 NewElastomeric Rod End 5 New Attaching Bolt DO New Washer oo Figure 3 Article 97 12 15 3 Measure the distance from the center of the ball stud to the collar of the clutch rod as shown Figure 3 Note this measurement 4 In addition mark the clutch rod to note the orientation of the ball stud in relation to the clutch rod NOTE THE ORIGINAL BALL STUD WAS CRIMPED ONTO THE CLUTCH ROD IN ORDER TO INSTALL THE NEW ELASTOMERIC ROD END THE ORIGINAL BALL STUD MUST BE REMOVED THIS MUST BE DONE CAREFULLY TO PREVENT DAMAGE TO THE CLUTCH ROD THREADS 5 Using a die grinder with a metal cutting bit carefully cut the original ball stud shank lengthwise making sure not to cut the threads of the clutch rod Several cuts can be made to ease removal 6 With the cuts made the ball stud can now be rotated off the clutch rod threads 7 Inspect the threads on the rod for damage necessary a die 3 8 24 UNF may be used to clean up the threads Refer to Figure 3 for Step 8 of the Service Procedure 8 Assemble the new Elastomeric Rod End F7HZ 7B537 CC onto the clutch rod a Thread the new Stop Nut 355571 S8 onto the clutch rod NOTE IT IS VERY IMPORTANT THAT THE NEW ELASTOMERIC ROD END BE INSTALLED IN THE SAME POSITION AND ORIENTATION AS THE ORIGINAL BALL STUD b Thread the new rod end onto the clutch rod until the same dimension is obtained
56. ctor 3 4x1 2 obtain locally into the water jacket penetration nearest engine centerline Refer to Figure 1 AIR COMPRESSOR COOLING CONNECTION CYLINDER HEAD REF VIEW IN DIRECTION OF ARROW RADIATOR QUIESCENT VENT LINE CONNECTION PORT FRONT VEHICLE 4997 Figure 1 Article 97 13 24 6 Connect upper hose connector coming out of the shutoff valve and Heater Core Inlet standard bulk hose or silicone hose with existing sleeve protector cut to 584mm 23 and secure hose at both ends with Hose Clamps 9 5 8287 Secure air compressor coolant hose to the other hose connector hose clamp in the T fitting with an existing hose clamp Figure 1 7 Into the other open water jacket penetration nearest lift hook install a 1 4x1 2 Bushing obtain locally then the Water Outlet Adapter 6 2 8 554 and the quiescent vent line 8 All fitting orientations shall be such that no hoses contact any other engine component 9 Refill engine coolant to correct level and check for leaks ES3HS BZB CA Hose Clamp F2HZ T18b8b C Heater Water Inlet Tube Assembly Obtain Locally 17251727 External x 1 2 Pipe Obtain Locally Connector S Bx1 2 FBHZ Bk554 4 Adapter Water Outlet Connector Obtain Locally Pipe Reducer Bushing FORA 10495 4 Heater Water Control Valve Assembly Obtain Locally Obtain Locally Obtain Locally Obtain Locally Obtain Locally Heater Hose Heater Hose S
57. e FEBRUARY 3 1997 No Start Starter Will Not Turn Engine Over Vehicles With FD1060 Engine Article No Starter Engine Will Not Turn Over Vehicles With FD1060 Engine 97 3 15 MEDIUM HEAVY TRUCK 1992 97 SERIES F amp SERIES SERIES ISSUE The engine may not crank on some vehicles This may be due to the starter motor not being robust enough for certain applications that are subject to frequent and or repeated starts and or vehicles which are operated in extremely cold weather ACTION If the starter motor requires service replace the motor with a revised more robust starter motor The new motor has been developed to have improved life in these severe operating conditions Refer to the following text for details NOTE FOR 1992 95 VEHICLES BUILT BEFORE 8 22 94 THE STARTER MOTOR WIRING MODIFICATION PROCEDURE OUTLINED IN TSB 94 26 13 MUST BE COMPLETED BEFORE THE REVISED MOTOR IS INSTALLED NOTE COMPLETE DIAGNOSING AND TESTING PROCEDURES FOR THE STARTING SYSTEM AND ITS COMPONENTS AND WIRING CAN BE FOUND IN SECTION 03 06 OF THE APPROPRIATE MODEL YEAR SERVICE MANUAL otarter motor removal and installation procedures can be found in Section 03 06 of the appropriate model year Service Manual NOTE TO EASE THE INSTALLATION OF THE NEW STARTER MOTOR ON VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION INSERT THE UPPER STARTER MOTOR ATTACHING BOLT THROUGH THE STARTER FLANGE BEFORE INSTALLING THE STARTER O
58. e Refer to the following Service Procedure for details SERVICE PROCEDURE NOTE THE INFORMATION IN THIS TSB ARTICLE APPLIES TO VEHICLES EQUIPPED WITH ELECTRIC STARTERS THAT HAVE A GROUND STUD VEHICLES EQUIPPED WITH AIR STARTERS WILL REQUIRE THAT THE NEW JUMPER GROUND WIRE BE ATTACHED DIRECTLY TO THE BATTERY NEGATIVE TERMINAL SINCE THE AIR STARTER DOES NOT CONTAIN A STUD Fabricate a new fan control ground circuit jumper wire using the following locally obtained components Approximately 1905mm 75 of 14 gauge wire e Butt connector 14 gauge with heat shrink insulation Eye connector 14 gauge with heat shrink insulation determine eye terminal size by measuring the starter motor ground stud diameter and then selecting the appropriate size terminal 1 Disconnect the negative battery cable For Steps 2 and 3 refer to Figure 1 Figure 1 Article 97 19 23 2 Locate the engine fan control module on the cowl panel just above the steering column outlet It be necessary to temporarily remove the air cleaner housing to gain access to the module 3 Disconnect the 14290 harness from the module 4 Open the 14290 harness and locate the module ground wire 57 BK The 57 BK wire connects to Pin B of the fan control module For Steps 5 7 refer to Figure 2 80 W GNW 38 D Fw S I I m m Description New Jumper Wire Modula Ground 5 14 gauge wire New Butt Connector 14 gauge w
59. e drain holes should be checked periodically to make sure they are not restricted A special Torca clamp is used to seal and connect the inlet exhaust pipe to the CCM This special clamp is required to properly close the Torca slots on the CCM inlet When installed on the CCM inlet the clamp bolt should not be positioned over one 1 of the four 4 Torca slots Instead the clamp bolt needs to be positioned between the slots in order to seal the connection properly Refer to Figure 4 Each new service will come equipped with a new Torca clamp These clamps are also available individually CLAMP AND SLOTS CLAMP POSITIONING THE TORCA CLAMP SHOULD BE INSTALLED SO THAT THE CLAMP BOLT IS POSITIONED BETWEEN THE SLOTS AND THE CLAMP IS FLUSH WITH THE FRONT EDGE OF THE INLET PIPE OF THE CCM THIS NOT THIS TH 4170 A Figure 4 Article 97 6 30 CCM DIAGNOSTIC PROCEDURES A CCM back pressure test should be performed when symptoms indicate excessive exhaust system back pressure may be causing engine driveability concerns such as low power hard starting black smoke or low turbocharger boost pressure A CCM back pressure test should also be performed following an internal engine turbocharger or fuel injector failure and repair These types of failures may allow engine debris and or excessive amounts of engine oil or fuel to accumulate on the catalyst and plug the CCM The result
60. e engine cooling fan should run all the time Circuit 721 can be found on the ECU connectors at the following locations CAT engines Pin 28 of Connector C110 e Cummins engines Pin C of Connector C171 e Detroit Diesel engines Pin Y3 of Connector C135 NOTE ON DDC ENGINES THE C135 CONNECTOR IS IN THE ENGINE HARNESS ABOUT 61cm 24 FORWARD OF THE ENGINE ECU Before the ECU will turn the engine cooling fan off it is programmed to check for a signal loop on the A C high pressure switch input to the ECU This signal is a loop between two 2 pins at the ECU that if broken or open will cause the engine cooling fan to run continuously This signal loop runs from CAT engines Pin 29 of Connector C110 to Pin 38 of Connector C110 e Cummins engines Pin 10 of Connector C170 to Pin T of Connector C171 e X Detroit Diesel engines ground of Pin H1 of Connector C135 Relay R 15 is wired into this signal loop R 15 will be normally closed allowing the signal loop to return to the ECU The ECU will then control the engine cooling fan based on engine requirements If the A C high pressure relay R 15 is opened or removed from the panel the ECU will assume high pressure and will turn the engine cooling fan on The A C high pressure relay R 15 is controlled by two systems e The high pressure switch if equipped e The fan clutch override switch if equipped The coil in the A C high pressure relay R 15 is powered by Circui
61. each side hole Complete this procedure for all six 6 new rivet holes PART NUMBER PART NAME W525174 5 OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME Jg 231b4A Repair Hood Bond 0 5 Hr DEALER CODING BASIC PART CONDITION CODE 16000 0 OASIS CODES 108000 111000 97 24 Publication Date NOVEMBER 24 1997 Cooling Fan Electrical Wiring Schematics Horton Kysor And Or Bendix On Off Fan Clutch Vehicles Equipped With Premium Diesel Engines Only Built Before Article No 10 7 96 97 24 30 Cooling Fan Diagnosis Information Horton Kysor And Or Bendix On Off Fan Clutch Vehicles Equipped With Premium Diesel Engines Only Built Before 10 7 96 MEDIUM HEAVY TRUCK 1996 98 AEROMAX LOUISVILLE ISSUE This TSB article will provide diagnostic information and wiring schematics for the Horton Kysor and Bendix engine cooling fan clutches ACTION If the engine cooling fan is not functioning properly refer to the following text and illustrations Figures 1 4 to aid in identifying the root cause of the concern Figure 1 Article 97 24 30 CATICUMMINS WITH HORTON FAN CLUTCH Figure 2 Article 97 24 30 Figure 3 Article 97 24 30 Figure 4 Article 97 24 30 DIAGNOSTIC INFORMATION NOTE THIS TSB PROVIDES SPECIFIC ENGINE COOLING FAN SERVICE INFORMATION FOR VE
62. eak Thermostat 8575 thin Seal Ring F7HZ 8255 AA and Thermostat Housing F7HZ 8592 AA onto the engine as shown in Figure 2 using the three 3 existing attaching bolts Torque the bolts to 42 57 N m 31 42 Ib ft Refer to Figure 3 EXISTING DEAERATION HOSE EXISTING HOSE CLAMP 5 NEW DEAERATION ENGINE CHECK VALVE JIGGLE PIN CYLINDER HEAD EXISTING COOLANT STAND PIPE EXISTING COOLANT TEMPERATURE GAUGE Figure 3 Article 97 1 17 NOTE FIGURE 3 PROVIDES A VIEW OF THE DEAERATION SYSTEM AND THE ENGINE COOLANT TEMPERATURE SENDER AS IT APPEARS ON 1996 97 VEHICLES AFTER THE INSTALLATION OF THE NEW DEAERATION CHECK VALVE JIGGLE PIN ON 1992 95 VEHICLES THE INSTALLATION OF THE ENGINE COOLANT TEMPERATURE SENDER VARIED THE CHANGE WAS OUTLINED IN TSB 95 20 12 FOR THESE VEHICLES THE COOLANT TEMPERATURE SENDER INSTALLATION SHOULD BE MODIFIED AS STATED IN TSB 95 20 12 THIS WILL PROVIDE A MORE ACCURATE COOLANT TEMPERATURE GAUGE READING 10 Remove the existing deaeration hose from the hose fitting 11 Remove the existing deaeration hose barb fitting and bushing from the coolant stand pipe assembly and discard The new deaeration check valve jiggle pin will replace both of these components 12 Install the new deaeration Check Valve Jiggle Pin 3926761 CF into the coolant stand pipe Be sure the threaded portion of the new check valve jiggle pin is first coated with a sealer or wrapped teflon tape pr
63. en and blue for identification In addition if the vehicle is equipped with a sleeper there will be a third ground system connector in this location that will need to be checked 6 With channel lock pliers carefully seat each connector completely Seating the connectors by hand will not supply sufficient force to completely seat the connectors 7 Reinstall the inner fender splash panel and the retaining screws OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME 1 Repair VViring Connections 0 4 Hr DEALER CODING BASIC PART CONDITION CODE 14290 33 OASIS CODES 203000 203200 Bulletin Contents TSB Article 97 8 3 has been superseded by Article 98 2 1 97 9 Publication Date APRIL 28 1997 Accessory Drive Belts Excessive Wear And Or Roll off Vehicles Equipped With Article No Detroit Diesel Engine 97 9 22 MEDIUM HEAVY TRUCK 1996 98 AEROMAX LOUISVILLE ISSUE The generator drive belts may wear excessively and or roll off the Front End Accessory Drive FEAD pulleys on some vehicles This may be caused by the belts oscillating excessively at certain engine roms ACTION Replace the current belts with revised belts The revised belts are banded and are less susceptible to oscillations This should reduce the belt wear and roll off concern Refer to the following Service Procedure for details SERVICE
64. erminal post C PART NUMBER PART HAME F Hz 14A20b5 BB Module Mounting Bracket FzZHz 134A amp 318 B Brake Override Module FzHz 14MNODD AA Ground Wire OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS INFORMATION ONLY OASIS CODES 201000 201200 301000 97 11 Publication Date 27 1997 Air Brakes Oil Leak At Air Brake Compressor Vehicles Built Through 4 1 97 Equipped With FD1060 Or FD1460 Engine And Air Brakes Article No Leak Oil Leak At Air Brake Compressor Vehicles Built Through 4 1 97 Equipped 07 11 24 With FD1060 Or FD1460 Engine And Air Brakes MEDIUM HEAVY TRUCK 1993 97 CARGO SERIES F SERIES L SERIES ISSUE The engine may leak oil between the air brake compressor and engine gear housing mating point on some vehicles This may be caused by the gasket not sealing properly between these two points ACTION Replace the original gasket with a revised Gasket The revised gasket has been redesigned to provide an improved sealing surface to reduce the possibility of oil leakage Refer to the following text for details The removal and installation procedures for the air brake compressor and the revised gasket can be found in the appropriate model year Service Manual Section 06 08A NOTE FOR THE REVISED GASKET TO PERFORM PROPERLY IT IS VERY IMPORTANT THAT THE AIR BRAKE COMPRESSOR BE MOUNTED SECURELY TO THE FRONT GEAR HOUSING MAKE SURE THE TWO 2 STUDS AND NUTS THAT SECURE THE AIR BRA
65. exhaust system emits white smoke during the initial warm up of the engine and or The white smoke continues even after the engine oil oil pan temperature reaches 57 66 135 150 F b C The engine oil oil pan temperature does not reach the 57 66 135 150 F Other driveability concerns exist then further diagnosis should be performed on the engine fuel and or cooling systems to determine the root cause of the concern Factors that can affect engine operation and white smoke are in the list that follows this paragraph Complete operation and diagnosis information on each system can be found in the appropriate model year Powertrain Drivetrain Service Manual and the Powertrain Control Emissions Diagnosis PC ED Service Manual e X Cooling system size volume auxiliary heaters cooling system hose routing use of shutoff valves etc Ambient temperature Fuel quality _ Engine starting aids what type how used e Time allowed for engine warm up at idle before beginning normal operation e X Engine base idle speed e X Cooling system specification fan clutch type viscous or on off winter fronts Cooling system operation thermostats fan clutch e X Engine operation base timing fuel injection pump injectors base engine etc NOTE TWO 2 TSB ARTICLES HAVE BEEN ISSUED THAT SPECIFICALLY RELATE TO THE ENGINE COOLING SYSTEM AND THE ENGINE S ABILITY TO ACHIEVE NORMAL OPERATING TEMPERATURES THESE TSB ARTI
66. gure 1 6 Then mark the intersection of the two 2 measurements and drill an 8mm hole through the sun visor Refer to Figure 1 7 Place the sun visor in position on the roof making sure that all six 6 attaching bolt holes are aligned Using the sun visor as a template mark the location in the roof that corresponds to the two 2 new holes in the sun visor 8 Remove the sun visor and drill a 13mm hole at each of the two 2 marks on the roof Refer to Figure 2 for the following Steps O FRONT OF Mem Description PertNumber Noles 1 Suvsr LLL 2 New Screw and Washer Assombly mE08881 5101 2 required 773 New Screw and Washer Assembly 08688 555 required 4 Existing isolator 22053740 place as needed _ Cs eem NewHveNu required 7 New Ciear Silicone Rubber Sealer DSAZ 19562 AA Stainless Steal Flatwashers Obtain locally size 5 16 or 3 9 required 3 for each outside diameter 1 thickness 1 8 new screw location 4863 Figure 2 Article 97 7 15 9 Install a new Rivet Nut N808712 S309 in the two 2 new holes and apply a small amount of Clear Silicone Rubber Sealer D6AZ 19562 AA or equivalent meeting Ford specification ESB M4G92 A onto the roof around the new rivet nut 10 Remove the protective paper from the new
67. he Front End Accessory Drive FEAD belt may have high wear and or may come off of the drive pulleys on some vehicles This may be caused by the belt tensioner support plate and or the idler pulley support plate not being flat This can cause the tensioner and idler pulleys to be out of alignment which results in accelerated FEAD belt wear and or belt roll off ACTION Replace the belt tensioner support plate and if equipped the idler pulley support plate The revised plate s should allow both pulleys to be in proper alignment which should reduce the possibility of belt wear and or belt roll off Refer to the following Service Procedure for details SERVICE PROCEDURE 1 Rotate the automatic belt tensioner using a 3 8 breaker bar or ratchet in the square of the belt tensioner arm to release drive belt tension With the tension released remove the drive belt from the tensioner Inspect the original drive belt for wear If it is still serviceable it may be reused If wear is noted replace the belt with a new Belt F3HZ 8620 F F B L Series and F3HZ 8620 K Cargo Series NOTE THE PARTS CATALOGUE INCORRECTLY CALLS OUT AN F3HZ 8620 M FOR SOME APPLICATIONS USE ONLY THE BELT LISTED IN THIS TSB ARTICLE NOTE IF THE DRIVE BELT NEEDS TO BE REPLACED AND THE VEHICLE IS EQUIPPED WITH HYDRAULIC BRAKES THEN THE HYDRAULIC BRAKE PUMP DRIVE BELT WILL HAVE TO BE REMOVED BEFORE THE SERPENTINE DRIVE BELT CAN BE REMOVED FROM THE ENGINE FOR REMOVAL
68. he engine rom and exhaust system back pressure results that were obtained during the test e g Engine Maximum rpm CCM Back Pressure inches of Hg H2O or kPa copy of the Warranty Repair Order with this information MUST be returned with the CCM The repair order should be placed into an envelope and attached directly to the CCM assemblies are mandatory return parts FCS 700 tag will be issued for each warranty replacement The failed CCM must be returned to the Warranty Parts Return Center WPRC 7655 Haggerty Road Canton Michigan 48187 Return the CCM freight prepaid Claims for freight reimbursement can be submitted by following the warranty freight reimbursement procedures outlined in the Warranty and Policy Manual Section 6 3 The failed CCM should be returned in the service CCM packaging Remove the CCM mounting straps if necessary to package NOTE IF MOUNTING STRAPS WERE THE CAUSE OF THE CCM FAILURE THE STRAPS MUST NOT BE REMOVED BOTH THE CCM AND STRAPS MUST BE RETURNED AS AN ASSEMBLY NOTE WARRANTY PAYMENT MAY BE DENIED IF THE CCM IS REPLACED FOR EXCESSIVE BACK PRESSURE AND THE ENGINE MAXIMUM RPM AND EXHAUST SYSTEM BACK PRESSURE TEST RESULTS ARE NOT WRITTEN ON THE WARRANTY REPAIR ORDER A COPY OF THE WARRANTY REPAIR ORDER WITH THIS INFORMATION MUST BE RETURNED WITH THE CCM THE REPAIR ORDER SHOULD BE PLACED INTO AN ENVELOPE AND ATTACHED DIRECTLY TO THE CCM PART NUMBER PART NAME FAHAZ SF 250 65 M
69. hub clutch assembly from the engine and place it on a work bench so that the mounting flange is accessible Refer to Figure 2 REAR VIEW KYSOR ON OFF FAN CLUTCH 141 0mm 5 55 o 9 7mm 0 38 EXISTING MOUNTING HOLES 4 30 0mm 1 197 60 0mm 2 387 5226 Figure 2 Article 97 21 17 7 Carefully mark the new attaching bolt locations on the mounting flange using the information provided in Figure 2 8 Drill two 2 9 7mm 0 38 holes at the locations marked 9 Reinstall the fan hub clutch assembly onto the engine using six 6 new Bolts N601212 S2 and six 6 new Washers 630068 2 Be sure to coat the bolts with Ford Threadlock 262 E2FZ 19554 B prior to installation 10 Torque the six 6 bolts to 22 33 N m 16 24 lb ft 11 Install the fan hub clutch air line 12 Install the serpentine drive belt 13 Install the fan assembly and torque the bolts to 42 57 N m 31 42 lb ft 14 Install the air charge cooler tube and torque the clamps to 2 3 N m 18 27 Ib in PART NUMBER PART HAME 1212 52 Balt NB3UDB8 82 Washer E2FZ 18554 B Threadlock 252 OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME 972117A Modify Fan Clutch Mounting Bracket DEALER CODING BASIC PART CONDITION CODE d OASIS CODES 402000 497000 97 22 Publication Date OCTOBER 27 1997 C
70. ing the fasteners removed in Step 2 Torque the bolts to 42 57 N m 31 42 lb ft 5 Using a 5 16 Clevis Pin 76007 S8 or equivalent install the cable yoke onto the hood bracket and secure with the retaining clip removed in Step 2 Install the cable spring onto the radiator support bracket as shown in Figure 2 CABLE ASSEMBLY CABLE SPRING FRONT OF M eras Figure 2 Article 97 20 20 PART NUMBER PART HAME F HZ 15B815 DA Hood Bracket F Hz 15828 CA Radiator Suppart Bracket F HZ 15B838 BA Cable Assembly OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME 9720204 Replace Hood Tilt Cylinder with Cable System DEALER CODING BASIC PART CONDITION CODE 1656616 2 OASIS CODES 112000 97 20 Publication Date SEPTEMBER 29 1997 Heater Poor Slow Heat And Or Coolant Leak Vehicles Equipped With DDC Series 60 CAT 3406 Or FD1460 Engine Built Through 6 11 97 Article No Cooling System Coolant Leak Poor Slow Heat Vehicles Equipped With DDC 97 20 21 Series 60 3406 Or FD1460 Engine Built Through 6 11 97 MEDIUM HEAVY TRUCK 1997 amp B SERIES LOUISVILLE ISSUE oome vehicles may have been built with a 45 degree elbow that is missing some threads The elbow is located within the heater plumbing and may result in a coolant leak and or poor slow heat ACTION Replace
71. ink two 2 electrical connectors e key engine running Powered Circuit circuit on which more than 6 volts are present e R 21 the fan control relay located on the instrument panel fuse panel R 15 the air conditioning high pressure relay located on the instrument panel fuse panel X Voltage Drop Test using a voltmeter to measure voltage differential by connecting the negative voltmeter probe on the negative battery post and the positive probe on the tested components ground measurement of more than 0 2 volts the tested components indicates poor ground circuit ON OFF FAN CLUTCH OPERATIONAL THEORY These vehicles use the electronic engine ECU to control the engine cooling fan operation This TSB does not apply to CAT 3126 electronic engines On CAT and Cummins engines the ECU will turn the engine cooling fan off by applying 12 volts to Circuit 721 which is wired to either Pin 1 or 2 of the fan control relay R 21 The opposite pin in the relay either 1 or 2 will contain a ground on Circuit 57 On Detroit Diesel engines the ECU will turn the engine cooling fan off by applying a ground to Circuit 721 which is wired to either Pin 1 or 2 of the fan control relay R 21 The opposite pin in the relay either Pin 1 or 2 will contain a 12 volt power source from Fuse 12 on Circuit 517 On all engines with no signal from the ECU the fan control relay R 21 should default to the fan on position i e th
72. ior to installation to reduce the possibility of coolant leaks 13 Install the deaeration hose onto the new check valve jiggle pin and tighten the hose clamp to 1 1 5 N m 9 13 10411 14 Reinstall and or reposition any components removed to gain access to the thermostat housing 15 Reinstall the negative battery cable 16 Refill the cooling system following the procedure provided in the appropriate model year Service Manual PART NUMBER PART NAME FY HZ 65 75 44 Thermostat 4 8255 Ring Seal Thin F HZ 8255 BA Ring Seal Thick FHL DI AA Thermostat Housing 39676 1 CF Check Valve OTHER APPLICABLE ARTICLES 95 20 12 WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME 3701174 Replace Thermostat And Deaeration system DEALER CODING BASIC PART NO CONDITION CODE 9575 11 OASIS CODES 208100 208999 402000 499000 97 1 Publication Date JANUARY 2 1997 e Engine FD1060 Or FD1460 High Vibration At Low Engine Article No Vibration High At Low Engine RPM Vehicles With FD1060 Or FD1460 Engine 97 1 18 MEDIUM HEAVY TRUCK 1992 97 SERIES F amp SERIES SERIES ISSUE High engine noise vibration harshness NVH at low engine rom may occur on some vehicles This may be caused by a reduction in cushioning of the rear engine mounts ACTION Replace the rear engine mount with a revised rear engine mount Refer
73. ith heat shrink insulation Existing Module Ground Wire 57 cut to accept new jumper wire New Starter Motor Ground Stud Eyelet Connector eyelet connector with 14 gauge wire connector and heat shrink insulation 5 Z la a e a 5222 Figure 2 Article 97 19 23 5 6 About 127mm 5 from the module connector cut the 57 wire Strip the module end of the 57 wire and install and crimp the new butt connector onto the wire Heat to seal the insulation On the harness side of the 57 wire use heat shrink tubing to seal off the end Reconnect the 14290 connector onto the fan control module Route the new jumper wire along the cowl across to the engine and down to the starter Use plastic wire ties to secure the wire in position The new jumper wire must be routed and secured to prevent it from interfering or chafing on other components For Step 10 12 refer to Figure 3 STARTER MOTOR STARTER MOTOR GROUND STUD uM Figure 3 Article 97 19 23 10 11 12 13 14 Remove the starter motor ground stud nut Install the new jumper harness eyelet onto the starter motor ground stud Install the ground stud nut Torque specifications for the ground stud nut based on the stud can be found in the Louisville AeroMax Service Manual Index If removed install the air cleaner housing assembly or any other components that may have been removed to gain access to perform
74. leeve Protector OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME 34713244 Relocate Hot Water Supply As Outlined 0 7 Hr DEALER CODING BASIC PART CONDITION CODE 15696 3 OASIS CODES 208000 208100 208999 97 14 Publication Date JULY 7 1997 Horns Air Horn Lanyard Is Loose And Or Pulls Free Vehicles Equipped With Article No Horns 07 14 24 MEDIUM HEAVY TRUCK 1996 98 LOUISVILLE ISSUE The air horn lanyard may become loose and or unattached from the air horn valve This may be due to the air horn valve fastener not being able to properly fasten the lanyard to the valve ACTION Replace the air horn and lanyard assembly The new valve and lanyard have been revised to reduce the possibility of the lanyard pulling away from the valve Refer to Section 13 01 of the appropriate Louisville AeroMax Service Manual for removal and installation procedures PART NUMBER PART BHz 13810 44 Air Horn valve And Lanyard Assembly OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME 14244 Replace Air Horn And Lanyard DEALER CODING BASIC PART CONDITION CODE 12910 i OASIS CODES 203000 205000 97 15 Publication Date JULY 21 1997 Article 97 15 29
75. ley Support Plate F3HZ 8678 AAA onto the engine with two 2 bolts and torque to 24 N m 18 lb ft Refer to Figure 2 NOTE AN IDLER PULLEY IS USED IN PLACE OF THE AIR CONDITIONING COMPRESSOR ON VEHICLES NOT EQUIPPED WITH AIR CONDITIONING THE IDLER PULLEY AND SUPPORT PLATE ARE ONLY AVAILABLE TOGETHER AS AN ASSEMBLY 9 Install the new belt or verify the original belt is wrapped properly around the crankshaft fan generator and A C compressor or idler pulley Figure 3 The belt must be completely seated in the groove of each pulley EZ 0 Part Number Description Z Part Number Description men Generator Suppor step Waternetsuppoteraact 9_ 3 wee rn caen _ Hydraulic Brakes Only 8 3D673 Hydro Max Auxiliary Drive Pulley BE 4475 4 Figure 3 Article 97 4 11 10 Position the drive belt on the inside of the automatic belt tensioner 11 With one hand rotate the tensioner to release the tension With the other hand guide the drive belt onto the water pump pulley Carefully release the tensioner to tighten the drive belt 12 Check again to verify the drive belt is properly positioned in all the drive pulley s grooves NOTE IF SO EQUIPPED REINSTALL THE HYDRAULIC PUMP DRIVE BELT BY REFERRING TO THE APPROPRIATE MODEL YEAR SERVICE MANUAL SECTION 03A 03 13 Start the engine and check the belt and belt tensioner for pro
76. n Level FD1060 Or FD1460 97 6 30 Diesel Engine Catalytic Converter Muffler CCM Possible Plugged CCM Due To Internal Engine Turbocharger Or Fuel Injector Failure Vehicles Built After 11 29 93 With 1994 Emission Level FD1060 Or FD1460 Diesel Engine MEDIUM HEAVY TRUCK 1994 97 CARGO SERIES F amp B SERIES L SERIES 1996 97 LOUISVILLE This TSB article is being republished in its entirety to include the latest level parts and to include vehicles built through the 1997 model year ISSUE To comply with 1994 Federal Emission requirements for Diesel Engines a Catalytic Converter Muffler CCM has been released for FD1060 and FD1460 midrange diesel engines ACTION This TSB article provides information on the CCM application design serviceability and testing procedures NOTE PERFORM TSB S 96 19 11 AND 97 1 17 WHEN PROCEEDING WITH THIS TSB ARTICLE CCM APPLICATION e X Only 1994 emission level engines are equipped with a CCM The word catalyst followed by a five 5 digit number will appear on the engine data plate if the engine is required to be equipped with a The engine data plate is attached to the side of the front gear housing in front of the fuel injection pump Refer to Figure 1 Certain 1994 engines vehicles built for export may not be equipped with a CCM A vehicle s model year and or build date are not absolute indicators of CCM usage To verify usage consult the engine data pla
77. nts F amp B And L Series With Engine Replace Rear Engine Mounts F amp B And L Series With FD145U Engine DEALER CODING BASIC PART NO CONDITION CODE 6070 OASIS CODES 497000 499000 703000 Noise Air Leak From Behind Instrument Panel Vehicles Built Through 10 21 96 97 1 Publication Date JANUARY 2 1997 Article No 97 1 19 MEDIUM HEAVY TRUCK 1996 97 AEROMAX LOUISVILLE ISSUE An air leak may be heard from one or more of the following accessory air valve assemblies Differential Axle Lock Fifth Wheel Engine Air Air Suspension Dump Wheel Lock These air valves are located on the right side of the instrument panel ACTION Replace the leaking valve with a new valve The new valve has been revised to reduce the possibility of an air leak Refer to the following Service Procedure for replacement details SERVICE PROCEDURE There are five 5 types of air valves currently available that operate various accessories The number of valves in a vehicle will depend on the options in the vehicle If an air leak is noted that is originating from behind the instrument panel locate the source of the leak If one of the air valve assemblies is leaking replace the valve using the following procedure 1 2 Disconnect the negative battery cable Remove the eight 8 Torx head screws that retain the RH instrument panel to the dash Carefully pull the instrument panel away from the
78. ooling Fan Electrical Wiring Schematics Diagnosis Information Horton And Or Kysor On Off Fan Clutch Vehicles Equipped With Electronic Premium Diesel Engine Vehicles Built After 10 7 96 Article No Cooling Fan Diagnosis Information Horton And Or Kysor On Off Fan Clutch 97 22 18 Vehicles With Premium Electronic Diesel Engine Vehicles Built After 10 7 96 MEDIUM HEAVY TRUCK 1997 98 AEROMAX LOUISVILLE ISSUE This TSB article will provide diagnostic information and wiring schematics for both the Horton and Kysor engine cooling fan clutches ACTION If the engine cooling fan is not functioning properly refer to the following text and illustrations to aid in identifing the root cause of the concern DIAGNOSTIC INFORMATION NOTE THIS TSB PROVIDES SPECIFIC ENGINE COOLING FAN SERVICE INFORMATION FOR VEHICLES EQUIPPED WITH A PREMIUM ELECTRONIC DIESEL ENGINE BUILT AFTER 10 7 96 ONLY ADDITIONAL SERVICE INFORMATION ON FAN CLUTCH OPERATION CAN BE FOUND IN OTHER TECHNICAL SERVICE BULLETINS IN SERVICE MANUALS AND THE ELECTRICAL AND VACUUM TROUBLESHOOTING MANUAL EVTM ON OFF FAN CLUTCH TERMINOLOGY e Electronic Control Unit ECU an electronic module used to control the operation of the engine e Fan Override Switch a toggle switch mounted on the instrument panel which activates the fan if the parking brakes are set e F P fuse panel A C air conditioning Jumper using a separate wire to l
79. per operation PART NUMBER PART NAME 8 14 Belt Tensioner Support Plate F3Hz gb7a AAA Idler Pulley Support Plate 3900631 CF Bolt Hex Head Flange F3HZ BB20 F 08 20 OTHER APPLICABLE ARTICLES 96 8 23 SUPERSEDES 96 25 29 WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME Replace Belt Tensioner Support Plate Only Replace Belt Tensioner Support Plate And Idler Pulley support Plate Additional Time H vehicle Is Equipped With Hydraulic Brakes DEALER CODING BASIC PART NO CONDITION CODE 22 OASIS CODES 497000 499000 97 4 Publication Date FEBRUARY 17 1997 Article 97 4 12 Cooling System Engine Cooling Fan Cracks At Center Hub MEDIUM HEAVY TRUCK 1991 97 L SERIES 1996 97 AEROMAX LOUISVILLE ISSUE The center hub of the 28 5 fan may crack around the mounting bolts due to the use of thin material at the center hub point ACTION Replace the fan with a revised fan The revised fan has a thicker steel mounting disc than the previous design Refer to the following Service Procedure for details SERVICE PROCEDURE 1 Remove the old fan 2 Refer to the following Application Chart and procure the correct revised fan and install 3 Torque the retaining bolts to 42 57 N m 31 42 lb ft NOTE IF USING A RUBBER MOUNTED FAN ON DETROIT DIESEL CORPORATION DDC ENGINES THE SPECIAL BOLTS NEED TO BE FIRST TORQUED
80. rage LABOR ALLOWANCE DEALER CODING OASIS CODES 204000 204100 204200 97 19 Publication Date SEPTEMBER 15 1997 Electrical Fan Clutch May Be Inadvertently Activated When Operating Some Electrical Accessories Vehicles With CAT 3306 Cummins M11 Cummins N14 FD1060 Or FD1460 Engine Vehicles With Air Operated On Off Engine Cooling Fan Clutches Engine CAT 3306 Fan Clutch May Be Inadvertently Activated When Operating some Electrical Accessories Vehicles With Air Operated On Off Engine Cooling Article No Fan Clutches 97 19 23 Engine Cummins M11 Or N14 Fan Clutch May Be Inadvertently Activated When Operating Some Electrical Accessories Vehicles With Air Operated On Off Engine Cooling Fan Clutches e Engine FD1060 Or FD1460 Fan Clutch May Be Inadvertently Activated When Operating Some Electrical Accessories Vehicles With Air Operated On Off Engine Cooling Fan Clutches MEDIUM HEAVY TRUCK 1996 98 AEROMAX LOUISVILLE This TSB article is being republished in its entirety to revise the Operation Time ISSUE The fan clutch may cycle on when electrical accessories such as turn signals headlamps etc are activated on some vehicles This may be due to the engine cooling fan control module ground circuit picking up interference from other electrical accessories and causing the module to falsely cycle the fan clutch ACTION Add a dedicated electrical ground wire for the fan control modul
81. ransmission 97 12 15 And 113 Inch Or 122 Inch Bumper To Back Of Cab Length MEDIUM HEAVY TRUCK 1997 98 AEROMAX LOUISVILLE ISSUE A rattling noise may be heard coming from the clutch linkage on some vehicles This noise is most prevalent when the vehicle is being driven under load at highway speeds This may be caused by vibrations generated by the engine transmission and driveline that are transmitted through the hard mechanical clutch linkage into the cab ACTION Replace the original clutch rod end with the new elastomeric rod end The new rod end has an internal rubber isolator which may reduce the amount of vibrations that can be transmitted through the clutch rod Refer to the following Service Procedure for details SERVICE PROCEDURE Refer to Figures 1 and 2 for Step 1 of the Service Procedure ORIGINAL CLUTCH PEDAL LINKAGE INSTALLATION Clutch Rod Ball Siud will be replaced Clutch Release Lever 2 3 Figure 1 Article 97 12 15 ORIGINAL CLUTCH ASSEMBLY INSTALLATION d OUTBOARD VIEW IN DIRECTION OF ARROW A PREVIOUS ILLUSTRATION BEFORE DISASSEMBLY NOTE THE POSITION OF THE CLUTCH ROD ASSEMBLY EITHER INBOARD OR OUTBOARD OF THE CLUTCH RELEASE LEVER THIS POSITION MUST BE MAINTAINED WHEN THE CLUTCH ROD IS REINSTALLED TOP VIEW hem Description 1 Clutch Rod Ball Stud 2 Clutch Rod Assembly __3_ Ball Stud Attaching Nut 23 _ 5 _ Glut
82. ressor support bracket with a new bracket The new bracket will provide additional support to reduce the possibility of oil leakage Refer to the following Service Procedure for details SERVICE PROCEDURE NOTE THIS PROCEDURE DETAILS THE REMOVAL AND INSTALLATION OF THE AIR BRAKE REAR SUPPORT BRACKET ONLY IF ENGINE OIL IS LEAKING FROM THE AIR BRAKE COMPRESSOR TO FRONT COVER ATTACHMENT POINT IT MAY BE NECESSARY TO RESOLVE THE ENGINE OIL LEAK BEFORE REPLACING THE BRACKET AS OUTLINED IN THIS TSB ARTICLE REFER TO THE APPROPRIATE MODEL YEAR SERVICE MANUAL FOR COMPLETE AIR COMPRESSOR AND GASKET REMOVAL AND INSTALLATION PROCEDURES Refer to Figure 1 FD1460 EXISTING INSTALLATION BRAKE AIR COMPRESSOR REAR SUPPORT BRACKET AIR BRAKE COMPRESSOR REF oi em a m VEHICLE Air Compressor Rear Support Bracket Bolts discard Compressor Rear Support Bracket discard L Figure 1 Article 97 10 11 1 Remove and discard the existing air compressor support bracket and the four 4 bracket retaining bolts Refer to Figure 2 FD1460 REVISED INSTALLATION BRAKE AIR COMPRESSOR REAR SUPPORT BRACKET AIR BRAKE COMPRESSOR REF 1 Original Engine Bracket __2 Original Engine Bracket Washers 8 Original Engine Bracket Bolts 5 Revised Air Compressor Rear Support Bracket TB 5034 A Figure 2 Article 97 10 11 2 Coat the four 4 new Bolts N807470 S36 with Loctite
83. s And Install Repair Kit DEALER CODING BASIC PART NO CONDITION CODE 004104 d OASIS CODES 108000 111000 701000 703000 97 7 Publication Date 31 1997 Fuel Injection Pump Bosch Service Information For FD1060 1460 Diesel Engines Article No Engine FD1060 Bosch Fuel Injection Pump Service Service Tip 07 7 16 Engine FD1460 Bosch Fuel Injection Pump Service Service Tip MEDIUM HEAVY TRUCK 1992 97 C SERIES F amp B SERIES L SERIES 1996 97 AEROMAX LOUISVILLE ISSUE There have been several requests from the field to clarify the Bosch warranty policy and procedures for components used on FD1060 and FD1460 engines ACTION Refer to the following text for service information regarding Bosch policies and procedure on warrantable repairs The Bosch warranty coverage on fuel injection components used on FD1060 and FD1460 engines is 2 years from a vehicle s warranty start date or 160 900 km 100 000 miles whichever comes first For vehicles that have exceeded the time and mileage limits of the Bosch warranty certain components may still be covered under the Ford warranty Specific information regarding the Ford warranty can be found in the Ford Warranty and Policy Manual If a Bosch component is suspect of failure it should be removed from the engine and brought to a Bosch Diesel Service Dealer DSD for diagnosis repair and or replacement It is very important that the DSD be
84. s of this will be excessive exhaust system back pressure and engine driveability concerns Other components in the exhaust system may affect the back pressure test The integrity of the entire system should be checked before the test is performed The engine data plate should be checked to determine the engine s rated rom and make sure the vehicle is equipped with a CCM before the test procedure is performed Refer to Figure 1 DIAGNOSTIC PROCEDURE CCM BACK PRESSURE TEST PROCEDURE CAUTION MAKE SURE VEHICLE PARKING BRAKE IS SET WHEELS BLOCKED TRANSMISSION IN NEUTRAL AND THE AREA AROUND THE VEHICLE AND THE ENGINE IS CLEAR BEFORE PERFORMING THIS TEST 1 Locate the back pressure test port 1 8 NPT fitting The test port for the single horizontal CCM and the single vertical CCM is located in the inlet end cap of the CCM The test port for the single horizontal CCM with vertical outlet pipe is located in the exhaust pipe just downstream of the engine turbocharger Install a pressure gauge Manometer with a range of 0 60 In 2 or 0 10 In Hg or 0 20 kPa onto the test port The Rotunda Diesel Engine Pressure Test Kit Gauge Bar 014 00761 has an appropriate gauge Determine the engine s rated rom This rated rom specification is located on the engine data plate Install a tachometer if vehicle is not 50 equipped Operate the engine until it reaches normal operating temperature Accelerate the engine to its high idle no load wide
85. t PART NUMBER PART NAME 2 14 4 4 1 14 14 4 4 FBHZ 14A454 D FBHZ 14 amp 454 E A 2 14 4 4 FBHZ 14A4B54 EC FBHZ 14A454 ED 14 4 4 FBHZ 14A454 FB 14 4 4 FBHZ 14A454 FD FBHZ 14 amp 454 F M FBHZ 14A454 LB F HZ 14A454 B A FrHZ 14A454 AA F H Z 14A454 AB F HZ 14A454 AC Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Kit Connector Repair Connector Repair Connector Repair Connector Repair Kit OTHER APPLICABLE ARTICLES NONE SUPERSEDES 96 23 23 WARRANTY STATUS INFORMATION ONLY OASIS CODES 203000 203200 97 11 Publication Date 27 1997 BRAKES 4 Flashers Do Not Function While Service Brake Is Applied Vehicles Article No With Signal Stat Turn Signal System 97 11 23 MEDIUM HEAVY TRUCK 1996 97 AEROMAX LOUISVILLE ISSUE An additional module is needed to allow the 4 way flashers to function with the service brakes applied depending on the vocation of the truck The standard Signal Stat multi function switch does not allow the 4 way flashers to function with the service brakes applied ACTION Install a new Brake Override Module The new
86. t 517 at Relay Pin 1 or 2 The opposite pin contains ground Circuit 90 which splits and runs to both the A C high pressure switch and fan clutch override switch Each of these switches supply ground necessary to power the A C high pressure 15 causing the relay to open and engine fan to come e lf the A C high pressure switch senses excessive pressure in the A C system the following will occur The A C high pressure switch closes grounding Circuit 90 e Relay R 15 will open causing an open in the signal loop to the ECU e The ECU will turn the engine cooling fan on until relay R 15 closes and the signal loop is restored or 3 minutes have elasped whichever occurs last e _ lithe driver switches the fan override switch to the on position the following will occur e The fan override switch grounds Circuit 90 The parking brake must be applied for the override switch to function e Relay R 15 will open causing a loss of the signal loop to the ECU e The ECU turns the engine cooling fan on During the vehicle build process the engine ECU is programmed to accept identify the options of the vehicle such as A C or the fan override switch If the ECU programming has been changed or is incorrect the operation of these systems and or the engine cooling fan clutch can be affected DIAGNOSIS All diagnosis begins with Figure 1 and ends with Figure 12 Start with Figure 1 and follow the diagnostic path for the specific fan clutch
87. te ENGINE DATA PLATE LOCATION 1994 EMISSION LEVEL ENGINE DATA PLATE THE 1994 EMISSION LEVEL ENGINE DATA PLATE HAS A SPECIFIC SECTION THAT INDICATES CATALYST USAGE A FIVE DIGIT NUMBER WILL APPEAR IN THIS SECTION IF THE ENGINE 15 EQUIPPED WITH A Im wa fr su ard waranty o E Timing DE ne ZIL P M H le la garantie si gde bil n noctu ste cron p oan asl rad CATALYTIC CONVERTER MUFFLER CCM cope Ae ooxceed MN shed iE el el hi 75 model sod appui kr Valve laah cold a int dv A TID EE at N i WI me sapr n u EE GA oe aes pulss maus E DE rn EL MINS ENGINE 45552 m di FO AD MOTOR company L Catalyseur No VEATIS SEHEN D pare ge pp herr ideri doux Sour Adm Advertiaed HP GR e a eme E 1991 EMISSION LEVEL ENGINE DATA PLATE THE 1991 EMISSION LEVEL ENGINE DATA PLATE DOES NOT HAVE A CATALYST USAGE SECTION Engling GE CUMMINS ENGINE co GA comin ESG et FORD MOTOR COMPANY d identite KO L Aur CEL na Tim ng T D C gt ate ro n c p al D Ux M al a Calar rs uf va ses Tor 273 model zum Valve cold A de passe kee ZINNEN conu AFEA po Ir Firing Order Fual rate at adv pi seri
88. temperature transmission temperature Fuel shut off solenoid F01460 Cummins electronic control module Heater blower motor Daytime running lamp module Alr valve switch speedometer Tachometer FbBHZ 14A4B54 D5 FBHZ 14A amp 4b4 DT FoHZ 144464 DU FbBHzZ 14A4Bb4 D F amp EHZ 14A464 DV FbBHZ 14A4b54 D7 FBHZ 14A454 E A FbHZ 14A4b4 EB 14 4 4 FBHZ 14A454 ED 14 454 F amp EHZ 14A464 FE FBHZ 144A454 FC FbBHZ 14A4b54 FD 14 454 M 14 454 1 2 14 454 14 4 4 7 14 2 14 4 PART NUMBER PART NAME 4 14 4 4 FBHZ 14A4b4 BB FBHZ 14A454 BC FBHZ 14A454 BD FBHZ 14A4b4 BE FBHZ 14A454 BF FBHZ 144 amp 454 BG FBHZ 14A4B54 B 1A FBHZ 14 A454 BIsA FBHZ 14A454 BLA FoH 144464 BMA FBHZ 14A454 BM FBHZ 14A amp 454 BF FBHZ 14A454 B 5 4 FBHZ 14A4b4 BTA FBHZ 14 A454 BLIA FBHZ 14A amp 454 B FBHZ 14 A454 B Y FBHZ 14A454 B ZA FbhHZ gt 14A454 C AA 14 454 FBHZ 14 A454 C CA 14 4 4 FBHZ 14A454 CEA FBHZ 14 amp 454 CF A FBHZ 14 A454 C GA FBHZ 14 A454 FBHZ 14454 C LA 4 14 4 4 14 4 1 2 14 4 4 14 4 4 2 14 4 4 FBHZ 14A454 CTA FBHZ 14A454 CLIA FBHZ 14 A454 CA FBHZ 14A4Bb4 C Y FBHZ 14 A454 C 7A 14 4 2 14 4 4 4 1
89. the 45 degree elbow in the heater plumbing Refer to the following Service Procedure for details SERVICE PROCEDURE 1 Verify the concern 2 Drain coolant following the procedure outlined in the appropriate Service Manual 3 Remove the 45 degree elbow fitting from location shown in Figures 1 through 4 and inspect for thread shortage CAT 3048 ENGINE MAIN VIEW 113 AND 122 BBC WITHOUT SLEEPER Figure 1 Article 97 20 21 Figure 2 Article 97 20 21 701460 ENGINE INCORRECTLY MADE PART CORRECTLY MADE PART 2 THREADED 1 2 FEMALE PIPE 2 02 FEMALE PIPE LESS 1 2 THREAD ON LIP d r L I 1 1 1 i mh 3 4 MALE PIPE x Y Figure 4 Article 97 20 21 A Replace the 45 Degree Elbow F7HZ 18599 SA fitting 5 Refill cooling system Verify the repair PART NUMBER PART F HZ 10599 55 45 Degree Elbow OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME 972021 Replace Fittings DEALER CODING BASIC PART NO CONDITION CODE 18599 OASIS CODES 208000 208100 208999 402000 Bulletin Contents TSB Article 97 20 22 has been superseded by Article 99 14 13 Bulletin Contents TSB Article 97 21 3 has been superseded by Article 99 12 10 Bulletin Contents TSB Ar
90. this repair Reconnect the battery ground cable OTHER APPLICABLE ARTICLES NONE SUPERSEDES 97 18 15 WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES 402000 499000 Bulletin Contents TSB Article 97 19 24 has been superseded by Article 98 25 7 Bulletin Contents TSB Article 97 20 1 has been superseded by Article 97 21 4 97 20 Publication Date SEPTEMBER 29 1997 Article No Hood Hood Tilt Cylinder Inoperative Vehicles Built Through 11 96 07 20 20 MEDIUM HEAVY TRUCK 1996 97 AEROMAX LOUISVILLE ISSUE The hood tilt cylinder may become inoperative This may be caused by motion between the hood and radiator support causing the seals and attaching components to fail ACTION Replace the hood tilt cylinder with a cable system The cable system is not sensitive to motion between the hood and radiator support Refer to the following Service Procedure for details SERVICE PROCEDURE 1 hood and support the hood from the ground 2 Remove the tilt cylinder and the two 2 mounting brackets and discard Also discard the clevis pin Refer to Figure 1 CLEVIS PIN RADIATOR SUPPORT BRACKET TILT CYLINDER Figure 1 Article 97 20 20 3 Install revised hood bracket onto the hood using the fasteners removed in Step 2 Torque the bolts to 9 13 N m 80 115 Ib in 4 Installrevised radiator support bracket onto the radiator support us
91. ticle 97 21 4 has been superseded by Article 98 9 3 97 21 Publication Date 13 1997 Cooling System Fan Clutch Attaching Bolts Loosen Vehicles Built Through 7 14 97 Article No Equipped With CAT 3126 Engine And Kysor On Off Fan Clutch 97 21 17 MEDIUM HEAVY TRUCK 1997 98 LOUISVILLE ISSUE The fan clutch attaching bolts may become loose on some vehicles equipped with the Kysor on off fan clutch This may be due to the original fan mounting hub not being robust enough ACTION Modify the existing mounting of the fan clutch hub and add two 2 additional attaching bolts The additional bolts should help prohibit the possibility of the fan hub from becoming loose Refer to the following Service Procedure for details SERVICE PROCEDURE Refer to Figure 1 GLUTGH WITH 26 F 1 L i Mem Description 2 Fa 2 9 Kysor Fan Clutch Assembly 4 Fan Clutch Air Line Fitting 5 Fan Clutch Air Line 8 Washer Bmmx17x2 25 Flat St TB 5225 A Figure 1 Article 97 21 17 1 Remove the RH side charge cooler pipe to access to the and fan clutch 2 Remove the cooling fan 3 Remove the serpentine belt 4 Disconnect the air line from the fan hub clutch assembly 5 Remove the four 4 bolts that attach the fan hub clutch assembly to the engine and discard 6 Remove the fan
92. tions Mounting straps will have to be ordered separately for those CCM s that do not already come equipped with mounting straps ee GAG NEW PARTS FOR CCM SYSTEM ENGINE MODELS PART NUMBERS _ DESCRIPTION 1 GRE 0L 0l j FD1D83 SHM F COWL BUS FTMZ SF2SIRYA MUFFLER CATERLYET FD1DGFD14B0 SHM LCE FIAZ 5FI50 ADB 4 MUFFLERACATALYST Sta SHM ELO PROFILE 2 250 3 5 FD D amp YFDi480 SYM LAGE 5 250 a SEE NOTE MUFFLER C ATALY ST 1400 SYO 7 2 5 250 AC 8 MU FFLERACATALYS7 621801460 SVO FFHEZSF2 XKFAD MUER FD10682 VM L A 8801 MUER ERACATAL 482 SWM 8501 8512 FAZ AE EF CATALYST 0801450 SHM 8501 FIHZBFREDAJS MU FELER CATALYST FO 1460 IHM L A 4613 FZMZ 5F250 AQ MUFFLEFV CATALYST de SYO UF L A 8501 FPHZ SF250 AH MUFFLERMATALFST FD1480 Sw UF L A 8513 F7HZ 5F2B50O AF MUFFLER ACATALYST FOIOSOFOI440 OF L AA 8501 F7HZ EF250 BB MUFFLERACATALYST FD 1460 SUD OF BB13 FFHZ EFZSO AM MUFFLER ATALYST FD1060 STM Bev F FBHASF250 GA MUFFLERACATALYST FD1080 STM oy L B501 2 5 250 23 MUFFLER CATALTST FD1480 Bev L Ssriss 2 25 MUER ESSCATAL ver 1460 STM L B501 8513 252 deo STM Dump L 8513 FBMZ MF250 F MUER eer
93. to the following Service Procedure for details SERVICE PROCEDURE NOTE 1992 93 VEHICLES WITH AN FD ENGINE WERE ORIGINALLY EQUIPPED WITH SOLID FRONT AND REAR ENGINE MOUNTS ISOLATORS TO RESOLVE NOISE VIBRATION HARSHNESS NVH CONCERNS TSB ARTICLE 95 23 15 SHOULD BE USED TO UPDATE THESE VEHICLES TO THE VOIDED STYLE MOUNTS ISOLATORS THE REAR ENGINE MOUNTS ISOLATORS PROVIDED IN THIS TSB ARTICLE SHOULD ONLY BE USED ON 1992 93 VEHICLES IF TSB ARTICLE 95 23 15 HAS ALREADY BEEN PERFORMED AND THE VOIDED REAR MOUNTS ISOLATORS HAVE SINCE COLLAPSED OR HAVE OTHERWISE FAILED 1994 97 VEHICLES WERE ORIGINALLY EQUIPPED WITH THE VOIDED MOUNTS AND THIS TSB ARTICLE SHOULD BE FOLLOWED WHEN REPLACING THE REAR MOUNTS ISOLATORS NOTE CONCERNS MAY BE CAUSED AND OR AMPLIFIED IF THE ENGINE IDLE SPEED IS SET BELOW SPECIFICATIONS THE ENGINE IDLE SPEED SHOULD BE CHECKED AND IF NECESSARY ADJUSTED TO THE SPECIFICATION PROVIDED ON THE ENGINE DATA PLATE THE POWERTRAIN CONTROL EMISSIONS DIAGNOSIS PC ED MANUAL SECTION 19A PROVIDES THE IDLE SETTING PROCEDURE Refer to Figures 1 2 and 3 for the following procedure REAR ENGINE MOUNTASOLATOR INSTALLATION FD1460 ENGINE SHOWN TRANSMISSION REFERENCE ISOLATOR esch WASHER 4 REQUIRED CAP WITH INTEGRATED SETSCREW REAR SPRING BRACKET REFERENCE WASHER 4 REQUIRED NUT 4 REQUIRED 4869 Figure 1 Article 97 1 18 POSITIONING REVISED REAR EN
94. ube to be sure the collet is properly retained on the tube 10 Reposition the instrument panel into the dash 11 Reinstall the eight 8 Torx head screws and torque to 2 5 3 5 N m 22 30 10 11 12 Reconnect the negative battery cable PART NUMBER PART NAME FAHZ A484 A 5 4454 4 FA HZ A44B84 D Alr Suspension F HZ 4484 EA Wheel Lock OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE Replace One 1 Or Two 2 Valves Replace Three 3 Valves Replace Four 4 Or Five 5 Valves DEALER CODING BASIC PART NO CONDITION CODE 4484 OASIS CODES 205000 301000 304000 702000 97 2 Publication Date JANUARY 20 1997 Doors Battery Access Doors Come Loose New Part Availability Vehicles Built Article No Through 9 96 97 2 17 MEDIUM HEAVY TRUCK 1996 97 AEROMAX LOUISVILLE ISSUE The fasteners for the battery access doors on vehicles equipped with lower body side panels may become loose This may be caused by the current fasteners not retaining torque Also the battery access doors were not serviced available individually and parts are now available ACTION Replace the existing door fasteners with new fasteners The new fasteners should retain their torque and reduce the possibility of the door coming loose Refer to the following Service Procedure for details SERVICE PROCEDURE Refer to Fig
95. uflerCatalyst FBHZ 5F 25D0 EA Mutfler Catalyst FBHZ 5F 250 F 4 Mutfler Catalyst FBHZ 5F 250 654 Mutfler Catalyst FBHZ 5F250 HA MlufflerCatalyst F HZ SF25D AB Muffler Catalyst F HZ SF250 AC Catalyst F HZ SF25D AD MuflerCatalyst F7 HZ 5F250 4E Muffler Catalyst F HZ SFZS8D AF MufflerCatalyst F HZ SF25D0 AG MuflerCatalyst F HZ 5F250 AH MutflerCatalyst F HZ SF250 AJ Mluffler Catalyst F HZ 5FZ50 AK MuflerCatalyst F HZ 5F250 BB Muffler Catalyst FY HAS FASO Y A Muffler Catalyst Fr HZ 5F250 ZA Mufler Catalyst DSHA5255 4 Outlet Pipe E5Hz 5255 A Outlet Pipe E1HF 5A231 H Outlet Clamp 4 5 215 Catalytic Converter Mutfler CCM Strap E HZ 5A215 B Catalytic Converter Mutfler CCM Strap FAHZ SDZ223 D Catalytic ConverterMuffler Strap FAHZ 5D223 E Catalytic Canverter Muffler CCM Strap PART NUMBER PART F5HzZ 552D3 A Water Drain Tube 55203 Water Dram Tube 375406 5101 Vater Drain Elbow FAHZ 3A IB5 C Label English FAHZ 3A B5 B Label French 5 221 Inlet Clamp Torca OTHER APPLICABLE ARTICLES 96 19 11 97 1 17 SUPERSEDES 95 5 28 WARRANTY STATUS Eligible Under Basic Warranty Coverage And Emissions Warranty Coverage For Return Details Refer To Warranty Claim Procedure In This TSB Article LABOR ALLOWANCE OPERATION DESCRIPTION TIME 9206305 Ferfarm Exhaust Back Pressure Test Hr DEALER CODING BASIC PART CONDITION CODE
96. ure 1 1 02000000 a Access Door 5 Panel Body Side Lower Figure 1 Article 97 2 17 1 Loosen the four 4 existing battery access door screws and remove the door from the body panel 2 Remove the existing screws from the door and discard 3 Remove the four 4 corresponding J nuts from the lower body panel and discard 4 Install four 4 new J nuts N623332 5100 onto the lower body panel at the location of the holes 5 Place the battery access door into position on the lower body panel and secure it with four 4 new Screws W701810 S300 and torque the screws to 10 13 N m 85 115 Ib in 6 Repeat this procedure for the opposite battery access door NOTE THE BATTERY ACCESS PANELS ARE NOW AVAILABLE INDIVIDUALLY IF ONE BECOMES LOST OR DAMAGED IT CAN NOW BE REPLACED REFER TO THE PARTS BLOCK AT THE END OF THIS TSB ARTICLE FOR CORRECT PART NUMBERS PART NUMBER PART HAME Nb23332 81010 701010 5300 2 291022 Access Door RH FYHZ 9029 1 0253 44 Access Door LH OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS Eligible Under Basic Warranty Coverage LABOR ALLOWANCE OPERATION DESCRIPTION TIME Replace Battery Access Cover Hardware Both Sides 0 5 Hr 3702174 Replace Battery Access Cover Hardware Side 0 3 Hr DEALER CODING BASIC PART CONDITION CODE 7020125 OASIS CODES 108000 111000 97 3 Publication Dat
97. y void the vehicle warranty for affected components as stated in the vehicle s warranty guide OTHER APPLICABLE ARTICLES NONE WARRANTY STATUS INFORMATION ONLY OASIS CODES 614000 614500 614600 Bulletin Contents TSB Article 97 19 10 has been superseded by Article 98 10 4 97 19 Publication Date SEPTEMBER 15 1997 Steering Wandering Or Darting After Contacting Uneven Pavement Vehicles With Article No 18 000 20 000 Lb Front Axle Dual Steering Gears And Additional Pusher Or Tag Rear 97 19 21 Axles MEDIUM HEAVY TRUCK 1996 98 LOUISVILLE ISSUE The vehicle may wander or dart after contacting uneven pavement This may be caused by the addition of aftermarket pusher axles or tag rear axles and their affect on the front end geometry ACTION Install new steering and suspension components Refer to the following Service Procedure for details SERVICE PROCEDURE NOTE THE SERVICE PROCEDURE IN THIS TSB ARTICLE PROVIDES ONLY A GENERAL GUIDELINE FOR DIAGNOSING AND REPAIRING A POTENTIAL STEERING WANDER OR DARTING CONCERN ON CERTAIN LOUISVILLE VEHICLES COMPLETE DIAGNOSTIC AND SERVICE INCLUDING PART REMOVAL AND INSTALLATION PROCEDURES AND FASTENER TORQUE SPECIFICATIONS INFORMATION FOR THE PARTS PROVIDED IN THE ARTICLE CAN BE FOUND IN THE APPROPRIATE YEAR LOUISVILLE AEROMAX SERVICE MANUAL SECTIONS 04 AND 11 CAUTION ON SOME VEHICLES IT WILL BE NECESSARY TO DRILL NEW MOUNTING HOLES FOR THE UPPER SHOCK BRACKET IN

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