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2003 Ford Truck Expedition Suspension – Air Suspension Height Sensor Linkage Loose Service Procedure

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Filed Under (Ford Manuals) by admin on 10-01-2012

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ISSUE Some 2003-2006 Expedition and Navigator vehicles equipped with an air suspension may exhibit an air suspension height sensor linkage arm disengaging from the suspension ball stud or height sensor rotating arm. This concern typically occurs with the rear sensor (Figure 1) but may occur with the front sensors as well. If this occurs, the symptom will typically be the vehicle leaning to one side, the vehicle sitting too low/high, a harsh ride, and/or an inoperative air suspension. In addition, this concern may result in diagnostic trouble code (DTC) C1725 (air suspension front pneumatic failure) or C1726 (air suspension rear pneumatic failure). ACTION When a linkage arm becomes disengaged, do not re-attach the arm and do not replace the sensor unless broken. Instead, install a revised linkage arm on all three (3) sensor assemblies, even if they have not detached from the ball stud. 1. Replace linkage arms on all three (3) sensor assemblies following Workshop Manual (WSM), Section 204-05. 2. Discard the old linkage arms. NOTE IF THE SENSOR ASSEMBLY NEEDS TO BE REPLACED FOR ANY DAMAGE/FAILURE OTHER THAN THE ONE DESCRIBED IN THIS TSB, THE REPLACEMENT ASSEMBLY IS SUPPLIED WITH A NEW STYLE LINKAGE ARM, SO THERE IS NO NEED TO ORDER ADDITIONAL LINKAGES FOR THE SERVICE REPAIR. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061510A 2003-2006 0.4 Hr. Expedition/Navigator: Replace The Three Linkage Arms, Includes Time To Check Diagnostic Trouble Codes (Do Not Use With 5300A, 5300A7, 5300A8) DEALER CODING CONDITION BASIC PART NO. CODE 5A967

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2003 GMC Truck C 1500 P/U 2WD Engine Knocking or Lifter Noise

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Filed Under (GMC Manuals) by admin on 30-06-2012

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Engine Lubrication: All Technical Service Bulletins Engine – Knocking or Lifter Noise File In Section: 06 – Engine/Propulsion System Bulletin No.: 02-06-01-038 Date: December, 2002 TECHNICAL Subject: Engine Knock or Lifter Noise (Replace 0-Ring) Models: 2001-2002 Chevrolet Camaro 2001-2003 Chevrolet Corvette 2001-2002 Pontiac Firebird 2002-2003 Cadillac Escalade, Escalade EXT 2000-2003 Chevrolet Suburban, Tahoe 2001-2003 Chevrolet Silverado 2002-2003 Chevrolet Avalanche 2000-2003 GMC Yukon, Yukon XL 2001-2003 GMC Sierra with 4.8L, 5.3L, 5.7L or 6.0L V8 Engine (VINs V, T, Z, G, S, N, U – RPOs LR4, LM7, L59, LS1, LS6, LQ9, LQ4) Condition Some customers may comment on an engine tick noise. The distinguishing characteristic of this condition is that it likely will have been present since new, and is typically noticed within the first 161-322 km (100-200 mi). The noise may often be diagnosed as a collapsed lifter . Additionally, the noise may be present at cold start and appear to diminish and then return as the engine warms to operating temperature. This noise is different from other noises that may begin to occur at 3219-4828 km (2000-3000 mi). Cause The 0-ring seal between the oil pump screen and the oil pump may be cut, causing aeration of the oil. Correction

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1997-2001 FORD EXPEDITION ELECTRICAL LAMP – AIR SUSPENSION LAMP ILLUMINATED – DIAGNOSTIC TROUBLE CODES (DTC’S) B2140 OR C2140 – RIDE HEIGHT RESET PROCEDURE

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Filed Under (Ford Manuals) by admin on 26-01-2012

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SUSPENSION, AIR SUSPENSION DIAGNOSTIC TROUBLE CODES (DTC’S) B2140 OR C2140 RIDE HEIGHT RESET PROCEDURE ELECTRICAL LAMP – AIR SUSPENSION LAMP ILLUMINATED – DIAGNOSTIC TROUBLE CODES (DTC’S) B2140 OR C2140 – RIDE HEIGHT RESET PROCEDURE SERVICE PROCEDURE AIR SUSPENSION DTC’S THAT ARE PRESENT NOTE BEFORE ADDRESSING B2140/C2140. DURING PDI (PRE-DELIVERY INSPECTION) IF WARNING “CK SUSP” LIGHT IS ON, PRIOR TO SENDING WARNING: BEFORE REPLACING ANY AIR TO SERVICE, VERIFY SWITCH IN UPPER RIGHT SUSPENSION COMPONENTS, HOISTING, KICK PANEL IS ON. THIS SWITCH IS TURNED JACKING, OR TOWING, DISCONNECT POWER OFF DURING VEHICLE SHIPMENT TO PREVENT TO THE SYSTEM BY TURNING OFF THE AIR MODULE FROM SEEKING TRIM HEIGHT WHILE SUSPENSION SWITCH LOCATED IN THE RIGHT SECURED DOWN FOR TRANSPORT. KICK PANEL AREA TO PREVENT VEHICLE NOTE DAMAGE OR PERSONAL INJURY. AN INADVERTENT B2140 OR C2140 MAY RAS ONLY – CLEAR 2140 RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE NOTE COMMANDS, THEN CANCELLED OUT. EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND NOTE TOGGLING FRONT TO “ON” TO CLEAR A CK THE AIR SUSPENSION CONTROL MODULE SUSP LIGHT/2140 CODE. THIS ALLOWS THE PART NUMBER IS INTERCHANGEABLE MODULE TO STORE THE VOLTAGE WITH NO BETWEEN THE REAR AIR SUSPENSION (RAS) FRONT HEIGHT SENSOR PRESENT, AND MUST AND 4-WHEEL AIR SUSPENSION (4WAS) BE DONE EVEN WITH CONVENTIONAL (STEEL SYSTEMS, BUT ONCE THE MODULE IS COIL) FRONT SUSPENSION. INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS)

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2004 Chevrolet TrailBlazer Noise Coming From Instrument Panel Cluster (Replace Instrument Panel Cluster (IPC)) Repair Manual

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Filed Under (Chevrolet Manuals) by admin on 18-02-2012

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This bulletin is being revised to add model years and provide important repair information. Please discard Corporate Bulletin Number 04-08-49-015 (Section 08 — Body and Accessories). Condition Some customers may comment on a noise coming from the instrument panel cluster (IPC) while driving or on initial start-up. Instrument clusters may contain stepper motor gages that can make noise during the following conditions: Subject: Noise Coming From Instrument Panel Cluster (Replace Instrument Panel Cluster (IPC)) Models: 2003-2005 Buick LeSabre 2003-2007 Buick Rendezvous 2004-2005 Buick Rainier 2003-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Cavalier, Impala, Monte Carlo 2003-2006 Chevrolet Avalanche, Suburban, Tahoe, TrailBlazer EXT 2003-2007 Chevrolet Silverado Classic, TrailBlazer 2003-2007 Chevrolet Kodiak Models 2004-2006 Chevrolet SSR 2003-2006 GMC Envoy XL, Yukon, Yukon XL 2004-2005 GMC Envoy XUV 2004-2007 GMC Envoy 2003-2007 GMC Sierra Classic 2003-2004 Oldsmobile Bravada 2003-2005 Pontiac Aztek, Bonneville, Sunfire 2003-2005 HUMMER H2 Attention: Appropriate repair is based on vehicle build date. Use GMVIS to determine the vehicle build date. • Initial startup (gages zero/reset)

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2003-2005 FORD Explorer Sport Trac Alignment – Irregular Front Tire Wear SERVICE PROCEDURE

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Filed Under (Ford Manuals) by admin on 09-06-2011

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ISSUE Some 2003-2005 Explorer Sport Trac vehicles equipped with the Goodyear Wrangler RT/S, P255/70R16 109S AT OWL tire, may exhibit signs of feathering heel-toe wear on the inside or outside edges of the front tires . Tire noise may also be present during regular highway drive or when braking. ACTION Inspect the tires for feathering heel-toe wear. It may be necessary to rotate or replace tires and reset toe. Refer to the following Service Procedure. SERVICE PROCEDURE Zoom Sized for Print 1. Visually inspect the front tire’s inside and outside shoulder ribs (Figure 1) 2. Measure the difference in tread depth of the leading edge compared to trailing edge, of the most-worn lug (figure 2). If the average difference in tread depth between leading and trailing edge is less than 2 mm, rotate the tires . If the average difference is more than 2 mm, replace the front tires. Also inspect the rear tires and replace if necessary. 3. Ensure that the camber and caster readings are within specification

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2003 Ford F-Super Duty 250-550/ Excursion Rear Drive Axle/Differential/ Ford 10.50-Inch Ring Gear Installation Manual

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Filed Under (Ford Manuals) by admin on 30-06-2012

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1. Remove the differential case. For additional information, refer to Differential Case in this section. 2. NOTE: The differential bearings need not be removed to overhaul the Ford limited slip differential. If bearing removal is required, for additional information, refer to Differential Case in this section. NOTE: The anti-lock speed sensor ring cannot be reused once removed. Remove the differential pinion shaft lock bolt and remove the differential pinion shaft. ? If required, remove the ring gear and anti-lock speed sensor ring. 3. NOTE: This tool does not have the 1/2-inch drive hole. Install the special tool in a suitable vise. 2003 F-Super Duty 250-550/Excursion Workshop Manual 5. Install the special tool in the bottom side gear bore. ? Apply a small amount of grease to the centering hole of the special tool. 6. Install the nut in the upper differential side gear. Hold the nut in position while installing the hex screw. Tighten the hex-head screw until contact is made with the Step Plat 2003 F-Super Duty 250-550/Excursion Workshop Manual 7. Insert a suitable dowel bar in the hole of the nut. Tighten the forcing screw to force the differential side gear away from the differential pinion gears. The dowel bar is used to keep the nut from turning when the forcing screw is tightened. NOTE: Differential pinion thrust washers cannot be removed independently of the differential pinion gears and so must be removed simultaneously with the differential pinion gears. Insert the special tool in the pinion shaft bore and turn the differential case to “walk” the differential pinion gears and differential pinion thrust washers out to the differential case windows. 9. Remove the differential pinion gears and differential pinion thrust washers. 10. Remove the differential side gears and differential clutch packs and tag them RIGHT and LEFT with the shim

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1997 Ford F-250/ 350/ Super Duty Steering Knuckle REMOVAL AND INSTALLATION MANUAL

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Filed Under (Ford Manuals) by admin on 13-06-2012

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Steering Knuckle Removal 1. Remove the front wheel spindle (3105) and the right and left shaft and joint assembly. Refer to Spindle, RH and LH Shaft and Joint Assembly in the Removal and Installation portion of this section. 2. Disconnect the steering linkage, if necessary, from the knuckle. Refer to Section 11-03 in the Body, Chassis Manual. Steering Knuckle Installation 3. Remove the cotter pin from the stud of the front suspension upper ball joint (3049). Loosen the nut on the top stud and the bottom nut inside the steering knuckle. Remove the top nut. 4. Sharply hit the top stud with a plastic or rawhide hammer to free the knuckle from the axle arm. Remove and discard bottom nut. 5. NOTE: Note the orientation of the camber adjuster to make sure of the same camber setting. Remove camber adjuster by hand or, if difficulty is encountered, use Pitman Arm Puller T64P-3590-F. 6. Place steering knuckle in vise and remove snap ring from bottom ball joint socket if so equipped. 7. Remove plug from U-Joint Tool T74P-4635-C and replace with Plug T80T-3010-A4 (part of 4WD Ball Joint Tool Set T80T-3010-A). 8. Assemble U-Joint Tool T74P-4635-C and Receiving Cup T80T-3010-A2 (part of 4WD Ball Joint Tool Set T80T-3010-A). 9. NOTE: Always remove front suspension lower ball joint first. Turn forcing screw clockwise until front suspension lower ball joint is removed from steering knuckle. 10. Repeat procedure and remove front suspension upper ball joint. Installation 1. Clean steering knuckle bore and insert front suspension lower ball joint as straight as possible. 2. NOTE: If ball joint cannot be installed to the proper depth, realign Receiving Cup T80T-3010-A3. To replace the front suspension lower ball joint, assemble U-Joint Tool, Receiving Cup T80T-3010-A3 (part of 4WD Ball Joint Tool Set T80T-3010-A) and Installing Cup from Ball Joint Adapter Set D81T-3010-A or equivalent. 3. Turn forcing screw clockwise until front suspension lower ball joint is firmly seated. 4. Install the snap ring on the front suspension lower ball joint. 5. To install front suspension upper ball joint, assemble the C-Frame, Receiving Cup T80T-3010-A3 and Replacer T80T-3010-A1 (both part of 4WD Ball Joint Tool Set T80T-3010-A). 6. Turn forcing screw clockwise until front suspension upper ball joint is firmly seated. 7. Assemble knuckle to axle arm assembly. Install camber adjuster on the stud of the front suspension upper ball joint with the arrow pointing outboard for positive camber, pointed inboard for negative camber. 8. Install new nut on bottom socket finger-tight. Install and tighten nut on top socket finger-tight. Tighten bottom nut to 47 Nm (35 lb-ft). 9. CAUTION: If the tightening sequence is not followed in this step and Step 10, ball joint life will be reduced. NOTE: Do not loosen top nut to install cotter pin. Tighten top nut to 136 Nm (100 lb-ft), then advance nut until castellation aligns with cotter pin hole. Install cotter pin. 10. Retighten bottom nut to 123-149 Nm (91-110 lb-ft). 11. Install the front wheel spindle and the right and left shaft and joint assembly as described in this section. 12. Connect steering linkage, if necessary, to the knuckle. Refer to Section 11-03 in the Body, Chassis Manual.

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2008 Ford Explorer/ Mountaineer/ Explorer Sport Trac Headliner REMOVAL AND INSTALLATION MANUAL

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Filed Under (Ford Manuals) by admin on 04-05-2012

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Explorer and Mountaineer only 1. If equipped, remove the rear entertainment system. For additional information, refer to Section 415-00 . Explorer Sport Trac only 2. NOTE: The headliner is removed through the rear passenger door. To facilitate removal, the front passenger seat must be removed. Remove the front passenger seat. For additional information, refer to Section 501-10 . All vehicles 3. Remove the overhead console. For additional information, refer to Section 501-12 . 4. Remove the A-pillar trim panel. For additional information, refer to A-Pillar Trim Panel in this section. 5. Position the B-pillar upper trim panel aside. For additional information, refer to B-Pillar Upper Trim Panel in this section. Explorer and Mountaineer only 6. Remove the C-pillar trim panel. For additional information, refer to C-Pillar Trim Panel — Explorer, Mountaineer in this section. 7. Remove the D-pillar trim panel. For additional information, refer to D-Pillar Trim Panel in this section. Explorer Sport Trac 8. Position the C-pillar upper trim panel aside. For additional information, refer to C-Pillar Upper Trim Panel — Explorer Sport Trac in this section. All vehicles 9. Remove the gimp around the roof opening panel, if equipped. 10. Remove the 4 sun visor retainer screws. 11. Remove the sun visors. 12. Carefully lower the headliner at the corner of the sun visor location to access the electrical connector and disconnect the electrical connector. 13. Disconnect the roof opening panel, if equipped. 14. Disconnect the interior mirror electrical connector and electronic compass sensor connector, if equipped. 15. Use a thin-blade tool and carefully remove the dome lamp cover. 16. Disconnect the dome lamp electrical connectors. Explorer and Mountaineer only 17. Remove the upper air duct. * Remove the pin-type retainers. * Push down on the duct, tilt the top outward and pull upward to remove. 18. Remove the lower air duct. 19. Disconnect the electrical connector located at the C-pillar. * Release the wiring harness pin-type retainers. 20. Disconnect all the electrical connectors. All vehicles 21. Disconnect the electrical connector and the wiring pin-type retainers on the A-pillar. 22. CAUTION: To prevent bending or damaging the headliner, an assistant is required to support the headliner while carrying out the remaining steps. Open the sun visor center retainer cover and remove the screw. 23. Remove the sun visor center retainer. 24. Remove the rear pin-type retainer. 25. CAUTION: To prevent damaging the garment hanger retainer, use a 3/16-inch flat-blade screwdriver to carry out this step. NOTE: The garment hanger is shown without the roof sheet metal screw to show the metal retainer clip. The metal retainer clip will remain engaged in the sheet metal after the garment hanger is removed. Remove the garment hangers. 1. Open the access door. 2. Insert the flat-blade screwdriver fully into the garment hanger slot. 3. Rotate the screwdriver 90 degrees so that the screwdriver spreads the metal retainer clip. Remove the plastic garment hanger. 26. NOTE: The headliner is removed through the passenger rear door for Explorer Sport Trac. Remove the headliner. 27. To install, reverse the removal procedure.

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1994-2003 Ford F-Series Power Stroke 7.3L Edge Evolution Programmer Installation Manual

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Filed Under (Ford Manuals) by admin on 25-05-2012

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Connecting the Evolution 1. Turn the ignition switch to the OFF position. Locate the diagnostic connector under the dash near the steering column or under the glove compartment and connect the Evolution cable to this connector. After making the connection, the screen will first display the Edge Products logo and then the main startup displays: The numbers in the upper left portion of the screen represent the version number of the Evolution programmer. The character in the upper right portion of the screen represents the current programmed state of your vehicle. The following letters may appear: I – Programming was interrupted. (See Programming Interrupted section for more information) 1 – Vehicle has been programmed to L1 – TOW. 2 – Vehicle has been programmed to L2 – RACE. 3 – Vehicle has been programmed to L3 – EXTREME. Evolution FORD Power Stroke 7.3 Liter 11 2. Select your desired option by pressing the up or down keys on the left side of the programmer and press . Continue to the next section. Evolution FORD Power Stroke 7.3 Liter 12 Power Programming “Caution: Vehicle manufacturers do not recommend vehicle programming in extreme temperature. Please see the service manual of your vehicle to ensure that programming is being done in accordance to the original equipment manufacturers specifications.” If you selected Diagnostics from the Main Menu, go to that section in this instruction manual and follow the steps. If you selected Performance from the Main Menu, go to that section in this instruction manual and follow the steps. If you selected Power Programming, the screen displays the following message: 1. After turning the key ON (do not start the engine) and pressing , the screen displays the following message: Evolution FORD Power Stroke 7.3 Liter 13 Evolution FORD Power Stroke 7.3 Liter 14 2. The Evolution will check the PCM and determine if it is in the Master Calibration list. If the calibration is available, you will see the following message: Otherwise you will see the following message (See Update Required for more information): 3. You will then be instructed to turn the key OFF, Press and turn the key back to ON (do not start) to begin saving STOCK: Evolution FORD Power Stroke 7.3 Liter 15 During the storing process, you will see the following display:
Evolution FORD Power Stroke 7.3 Liter 16 4. If this is the first time the unit is used on a particular vehicle, the Evolution will build and verify the modified calibrations (Skip to step 5 for subsequent programming operations). During this process, you will see the following displays

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LEAKS FROM REAR HALFSHAFT AXLE SEAL REPAIR MANUAL

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Filed Under (More Manuals) by admin on 15-06-2012

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FORD: LINCOLN: 2002-2006 Explorer 2003-2005 Aviator 2003-2006 Expedition 2003-2006 Navigator MERCURY: 2002-2006 Mountaineer This article supersedes TSB 05-15-5 to update the 3. Do not use a damaged seal installation tool vehicle model years, Parts, and Service Procedure. exhibiting nicks, burrs, or sharp edges. NOTE ISSUE THE USE OF SEAL PROTECTOR 1L2W-4N206-AA Some 2003-2006 Expedition/Navigator, 2002-2006 IS NO LONGER REQUIRED. Explorer 4dr/Mountaineer, and 2003-2005 Aviator vehicles equipped with the 8.8? or 9.75? ring gear 4. Do not tap directly on the back of the seal and independent rear suspension (IRS), may exhibit installation tool, always tap on the handle, per leaks at the rear halfshaft axle seals. A new Instruction Sheet. Seal should be driven evenly unitized seal is now available for service. The new into housing bore with only enough force to seal design eliminates the need to use seal seat in the bore. protectors during installation. Removal of the excluder seal (1L2W-1N013-BA) if present is 5. Before installing the halfshaft, verify that the required. inboard excluder seal (1L2W-1N013-BA) is not present on the halfshaft. If the excluder seal is ACTION present, follow the kit Instruction Sheet and Order and install the new seal kit to correct the leak remove the excluder seal. condition. Review the updated instruction sheet NOTE included in the kit and obtain the required tools before beginning repair. OVERFILLING THE AXLE CAN INCREASE POTENTIAL FOR LEAKS. INSTALLATION SERVICE TIPS PART NUMBER PART NAME Refer to the appropriate Workshop Manual, Section 7L1Z-4A109-B Axle Shaft Seal Kit (9.75 Axle) 205-02 for half shaft removal and installation. 7L1Z-4A109-C Axle Shaft Seal Kit (8.8 Axle) NOTE IN THE WORKSHOP MANUAL UNDER THE HALF WARRANTY STATUS: Eligible Under Provisions Of SHAFT REMOVAL/INSTALLATION SECTION New Vehicle Limited THERE ARE ADDITIONAL PARTS CALLED OUT Warranty Coverage THAT ARE REQUIRED TO BE REPLACED. OPERATION DESCRIPTION TIME THESE PARTS ARE NOT INCLUDED IN THE 062205A 2003-2006 0.8 Hr. AXLE SHAFT SEAL KIT LISTED. Expedition/Navigator: Replace Rear Axle (Stub) 1. Use only the proper seal installation tool, Lisle Shaft Seal Includes Time Special Seal Installer (LIS 17850) available To Remove And Install through the Rotunda Technician Tool Program. Halfshaft One Side (Do Not Use With 4139A, 2. Ensure the seal installation tool is clean and 4139A2) free of debris prior to inserting into new seal.

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