ISSUE b. If new level (47 fin) rotors are present, Some 2004/2005 F-150 vehicles built before perform one (1) of the following: 11/29/2004 may exhibit front brake roughness and or shudder while braking. (1) If rotors are within minimum thickness specifications, machine the rotors using ACTION the Rotunda on vehicle brake lathe and Service the rack and pinion, rotors, and caliper the Rotunda adapter kit 201-R0093. assemblies as needed, based on vehicle build date Refer to the Workshop Manual, Section and current part levels installed on the vehicle. 206-00 for the correct on-vehicle brake Refer to the following Service Procedure. lathe procedure. SERVICE PROCEDURE (2) If rotors are beyond machinable thickness, the front rotors must be 1. Vehicles built prior to 8/20/2003 require the replaced. replacement of the rack and pinion assembly if it has not been replaced. Refer to Workshop 3. Install new service fix calipers. Manual, Section 206-03 and 211-02. NOTE 2. Determine if the vehicle has the old or new REPLACE CALIPERS WITH NEW SERVICE FIX level rotors (Figure 1). CALIPER ASSEMBLIES BY REMOVING THE CALIPERS AT THE KNUCKLES. THE SERVICE REPLACEMENT CALIPERS WILL BE PRE-ASSEMBLED WITH ANCHOR, SPRINGS, AND PADS. THE CALIPERS SHOULD BE INSTALLED AS A UNIT WITHOUT DISASSEMBLY. PART NUMBER PART NAME 6L3Z-2B120-A Caliper Asy (Right Side) 6L3Z-2B121-A Caliper Asy (Left Side) 5L3Z-1102-AB Rotor (4X2, 6 Lug) 5L3Z-1102-BA Rotor (4X2, 7 Lug) 5L3Z-1125-AA Rotor (4X4, 6 Lug) 5L3Z-1125-BA Rotor (4X4, 7 Lug) 6L3Z-3504-AA Steering Gear (Super Cab/Crew 4X2) 6L3Z-3504-BA Steering Gear (Super Cab/Crew 4X4) Figure 1 – Article 05-21-19 6L3Z-3504-CA Steering Gear (Regular Cab 4X2) 6L3Z-3504-DA Steering Gear (Regular Cab 4X4) a. If old level rotors, replace the front rotors 6L3Z-3C294-AA Retainer Spindle Nut and front caliper assemblies. Refer to Workshop Manual, Section 206-00 for front rotor and caliper replacement.
This article supersedes TSB 07-5-7 to update the NOTE Parts. SETTING TIRE PRESSURE TO DOOR SPECIFICATION IS ONE OF THE SINGLE MOST ISSUE IMPORTANT MEASURES IN RESOLVING THIS Some 2005-2007 F-Super Duty vehicles may exhibit ISSUE. LOWERING TIRE PRESSURE WILL MAKE steering wheel oscillation (back and forth motion), THIS ISSUE WORSE. immediately following front or rear wheel impacts ROAD TEST (i.e. pavement joints, frost heaves, rough roads, etc.). Steering wheel motion is typically in the range 1. Ask customer what type of road surface and of ± 5 degrees, and typically dampens out in fewer speed generates the steering wheel oscillation. than five oscillations. This condition occurs mostly on F-250/F-350 4X4 vehicles, and is more evident 2. Road test vehicle on similar road surface and on trucks equipped with a gas engine. speed, to gain a feel for the customer’s issue. ACTION 3. If no issues are identified during the road test, do not proceed with the rest of this TSB. Refer to the following Service Procedure to minimize the steering wheel oscillations on impacts, STEERING DAMPER however, there may be some remaining minor INSPECTION/REPLACEMENT AND oscillation which would be considered normal. STEERING/SUSPENSION FASTENER TORQUE CHECK SERVICE PROCEDURE SUMMARY F-250/F-350 4X4 Applications: 1. Set tire pressure and road test vehicle to evaluate vehicle before proceeding with further 1. Remove existing steering damper and frame repairs. If issue is resolved, do not proceed attachment bracket. with the rest of this TSB. 2. Replace steering damper and frame mounting 2. If concern still exists, install a new steering bracket with steering damper and frame damper (frame-mounted bracket and steering bracket. damper assembly on F-250/F-350 4X4 applications only). For F-250/F-350 4X2 and all 3. Attach steering damper to frame bracket and F-450/F-550 applications, inspect damper for torque bolt to 76 lb-ft (103 N•m). leaks and replace if necessary, torque steering 4. Assemble bracket and shock assembly to the and suspension fasteners per Workshop frame with attachment bolt retainer pointing to Manual (WSM). rear of vehicle. Torque frame bracket nuts to 59 3. If concern still exists, check front alignment and lb-ft (80 N•m). reduce front caster. 5. Attach other end of shock to the steering drag 4. Replace redundant control steering wheel (if link and torque to 66 lb-ft (90 N•m). equipped and vehicle built prior to 10/8/2004). 6. Install damper bolt cap to assure a friendly VEHICLE INSPECTION – TIRE PRESSURE surface for the battery cable in case of casual contact. 1. Set tire pressures as indicated on the vehicle label (located on driver’s door label).
Engine Systems Chapter 1 3-Cylinder Diesel Engine 3-Cylinder Diesel Engine – Description and Operation 3-Cylinder Diesel Engine – Overhaul Chapter 2 4-Cylinder Diesel Engine 4-Cylinder Diesel Engine – Description and Operation 4-Cylinder Diesel Engine – Overhaul Chapter 3 Cooling System Cooling System – 3-Cylinder Engine Description and Operation Cooling System – 4-Cylinder Engine Description and Operation Cooling System – Overhaul Chapter 4 Troubleshooting, Specifications and Special Tools Troubleshooting Specifications Special Tools Part 2 Fuel Systems Chapter 1 Fuel System – General Fuel System – Description and Operation Fuel System – Adjustments DPA Distributor Type Fuel Injection Pump Fuel System – Adjustments DPS Distributor Type Fuel Injection Pump Fuel System – Fuel Tanks, Filters and Fuel Lines Overhaul Chapter 2 Fuel Injection Pump – DPA Distributor Type Fuel Injection Pomp – Description and Operation Fuel Injection Pump – Overhaul Fuel Injection Pump – ISO Test Conditions Fuel Injection Pump – Test Procedures Chapter 3 Fuel Injection Pump – DPS Distributor Type Fuel Injection Pump – Description and Operation Fuel Injection Pump – Overhaul Fuel Injection Pump – ISO Test Conditions Fuel Injection Pump – Test Procedure Chapter 4 Injectors Ford 455C Injectors – Description and Operation Injectors – Overhaul Chapter 5 Injectors Ford 555C and 655C Injectors – Description and Operation Injectors – Overhaul Chapter 6 Air Cleaners Dry Type Air Cleaner – Description and Operation Dry Type Air Cleaner – Overhaul Chapter 7 Turbocharger Turbocharger – Description and Operation Turbocharger – Overhaul Chapter 8 Troubleshooting, Specifications, Test Plans and Special Tools Troubleshooting – Diesel Engines Troubleshooting – Turbocharger Specifications Special Tools Test Plans Part 3 Electrical System Chapter 1 Wiring, Lights and Controls Wiring, Lights and Controls – Description and Operation Wiring, Lights and Controls – Fault Finding and Repair Circuit Diagrams and Wiring Harness Chapter 2 Battery
Battery – Description and Operation Battery – Maintenance and Tests Chapter 3 Starting System Starting System – Description and Operation Starting Motor – Overhaul Chapter 4 Charging System – A127 55 Amp Alternator with Integral Regulator Charging System – A127 55 Amp Alternator with Integral Regulator – Description and Operation Charging System – A127 55 Amp Alternator with Integral Regulator – Service Precautions, Preliminary Checks, Initial Tests and Alternator Component Tests Charging System – A127 55 Amp Alternator with Integral Regulator – Overhaul Chapter 5 Troubleshooting, Specifications and Special Tools Troubleshooting Specifications Special Tools Part 4 Power Reversing Transmission Chapter 1 4×4 Fully Synchronized Power Reversing Transmission Power Reversing Transmission – Description and Operation Introduction to Overhauling the Transmission Gear Shift Lever, Modulator Unit and Solenoid Control Valve – Overhaul Front End Overhaul Complete Overhaul Component Overhaul Chapter 2 8X8 Fully Synchronized Power Reversing Transmission Power Reversing Transmission – Description and Operation Introduction to Overhauling the Transmission Gear Shift Lever, Modulator Unit, Lockup Valves and Solenoid Control Valve – Overhaul Front End Overhaul Complete Overhaul Component Overhaul